The Key Role of High-Performance Batteries in the Commercialization of Manned eVTOL Aircraft

The commercialization of manned eVTOL (electric Vertical Take-Off and Landing) vehicles is on the horizon, and the development of high-performance power batteries is becoming a critical factor in this process. Recently, EHang Intelligent, through its subsidiary Guangdong EHang General Aviation Co., Ltd., along with its joint venture Hefei HeYi Aviation Co., Ltd., received the first batch of operational certificates for manned civilian unmanned aerial vehicles (UAVs) from the Civil Aviation Administration of China (CAAC). This marks the beginning of a new era in low-altitude flight services.

As a core supplier in the eVTOL market, power battery companies are eagerly entering this emerging low-altitude economic sector, playing a pivotal role in the push for eVTOL commercialization. However, many industry experts believe that the current comprehensive performance of batteries still falls short of market demands, which could hinder the expansion of eVTOL applications. Key challenges remain in achieving longer flight ranges while ensuring safety and reliability.

From the perspective of major manufacturers, there is a consensus on accelerating the research and industrialization of semi-solid and solid-state batteries, as well as matching ultra-fast charging networks while forming deep partnerships with leading companies.

Following the acquisition of the operational certificate, EHang Intelligent will have secured all four necessary certifications, including the Type Certificate (TC), Airworthiness Certificate (AC), and Production License (PC), signifying the formal commencement of the commercialization phase for low-altitude manned services. In the near future, consumers will be able to purchase tickets in cities like Guangzhou and Hefei to experience low-altitude tours and urban sightseeing services.

Similarly, in March of this year, another prominent player in the low-altitude economy, Xpeng Huitian, issued targeted notices to battery manufacturers such as Funeng Technology and EVE Energy to accelerate their industrialization processes. According to their plans, the company’s modular flying car, dubbed the “land carrier,” is expected to achieve mass production by 2026. Additionally, the cargo variant of the Fengfei Aviation model has already obtained the TC and PC certifications, while the five-seat manned version is anticipated to complete airworthiness certification by 2026. Other companies, such as Wofei Chang Kong, Zero Gravity, and Shidi Technology, are also accelerating the certification process for their eVTOL products.

As eVTOL commercialization approaches, a new industrial chain landscape is unfolding, with companies eager to carve out their share in this burgeoning market. Industry insiders note that 70% to 80% of eVTOL components overlap with those of electric vehicles, making power batteries a pivotal component that stands to benefit significantly from the eVTOL industry’s growth. According to a report from CICC, the combined value of motors, batteries, and avionics—collectively referred to as the “three electrics”—constitutes a staggering 70% of the overall value of eVTOL aircraft, with battery costs accounting for approximately 20% of total expenses.

Compared to electric vehicles, eVTOL products exhibit a relatively lower sensitivity to battery prices, allowing for greater innovation potential in battery technologies. This could accelerate the adoption of cutting-edge technologies and enhance profit margins. According to Meng Ke, Chief Analyst at Zhen Lithium Research, battery manufacturers view eVTOL battery development as a crucial area for competition and a new profit growth avenue.

Back in 2023, CATL launched its condensed state battery, currently collaborating on a project involving civilian electric manned aircraft, adhering to aviation-grade standards and testing. Guoxuan High-tech has signed a strategic cooperation agreement with EHang Intelligent to jointly develop power cells, battery packs, energy storage systems, and charging infrastructure based on eVTOL products. Zhongxin Innovation Aviation is developing a high nickel/silicon battery series for low-altitude flight, intending to release its “Top Flow High Energy – Super Flight Battery” in 2024. EVE Energy has been working closely with an overseas company for several years, delivering A-sample products and assisting clients with obtaining relevant aviation certifications. Funeng Technology has already commercialized the first generation of eVTOL semi-solid battery cells, with the second generation expected to enter mass production by 2025.

New players like Xinjie Energy, Shanghai Xiba, and Jinyu New Energy are also targeting the high-performance battery sector, actively adapting to eVTOL manufacturers and seeking to establish differentiated competitive advantages. The industry’s focus is on achieving “high safety, high energy density, high discharge rates, and fast charging” capabilities. According to Meng Ke, eVTOL places exceptionally high demands on battery performance, presenting significant technical challenges. Currently, there is no standardized product across various manufacturers.

From a cost perspective, the manufacturing expenses for eVTOL batteries are still high due to the limited volume production, with R&D and production line costs being disproportionately allocated. These costs are at least three to five times higher than those of conventional power batteries. Guoxuan High-tech’s eVTOL business head, Xu Pengfei, noted that most eVTOL manufacturers prefer to collaborate with large battery companies that possess substantial R&D capabilities, considering product safety, performance, and advanced manufacturing processes.

In interviews, it was revealed that there is a general expectation for eVTOLs to achieve “high safety, high energy density, high discharge rates, and fast charging.” Xu Pengfei emphasized the paramount importance of flight safety in eVTOL battery development, focusing on enhancing the electrochemical and thermal stability of batteries through materials and structural innovations. Moreover, leveraging scaled manufacturing capabilities is crucial for improving battery yield and consistency to ensure system safety.

Beyond reliability and safety, there is ongoing industry effort to enhance eVTOL battery energy density, discharge rates, and fast-charging capabilities. The discharge rate determines whether an eVTOL can take off, while energy density impacts how far it can fly, and fast-charging capability influences overall flight efficiency. These three aspects are interrelated. During takeoff or rapid movement, eVTOL batteries must quickly release high current to achieve the necessary discharge rates. The industry commonly uses “C” to indicate discharge rates; for instance, 1C signifies completion of discharge in one hour, while 2C implies discharge in half an hour. Notably, eVTOL requires sustained discharge rates of 4C to 5C or even higher for stable takeoff and landing power performance, while conventional electric vehicles typically range from 1C to 2C. The prevailing method for enhancing sustained discharge rates involves reducing internal resistance through structural improvements and optimizing electrolyte and conductive agent formulations.

Energy density remains a critical topic in power batteries, particularly in the eVTOL sector. The condensed state battery released by CATL for electric manned aircraft boasts a maximum energy density of 500Wh/kg; Funeng Technology’s second-generation eVTOL semi-solid battery cell, set to enter mass production soon, exceeds 330Wh/kg; Guoxuan High-tech has developed a soft-pack semi-solid battery with an energy density of 360Wh/kg, targeting clients in low-altitude flight sectors; Zhongxin Innovation Aviation’s “Top Flow High Energy – Super Flight Battery” reaches 350Wh/kg; and BAK Battery is pursuing a semi-solid product with an energy density of 320Wh/kg for the eVTOL market.

It is important to acknowledge that while the “high safety, high energy density, high discharge rates, and fast charging” criteria reflect different performance dimensions of eVTOL batteries, achieving balance among them can present challenges. For instance, to meet high energy density requirements, manufacturers often opt for “high nickel ternary cathodes and silicon anodes,” which exhibit strong activity but may compromise safety. Likewise, high discharge rate demands may necessitate lower material packing densities, sacrificing some energy density in the process. Currently, various manufacturers implement different packaging approaches for eVTOL batteries. Guoxuan High-tech is pursuing both large cylindrical and soft-pack battery formats; Funeng Technology is focusing on soft-pack solutions; EVE Energy primarily employs soft-pack designs; Zhongxin Innovation Aviation is concentrating on high nickel 46 large cylindrical batteries; and BAK Battery has laid out a technical roadmap from small cylindrical to large cylindrical batteries.

Each packaging approach has its advantages and disadvantages, requiring battery manufacturers to customize their development in line with client needs. Cylindrical battery cases provide high strength, explosion resistance, and thermal stability, allowing for flexible assembly and standardization, though they may result in some volume inefficiency. In contrast, soft-pack batteries, made with aluminum-plastic or steel-plastic films, are lighter, more efficient in assembly, and offer higher energy density, although their thermal protection and safety performance still require enhancement.

While eVTOL battery products are continuously being innovated, the expansion of application scenarios is accompanied by rising market demands for battery performance. Currently, the primary eVTOL applications include tourism, firefighting, and short-distance cargo transport. Future applications may extend to urban air mobility and intercity transportation, necessitating advancements in battery range and refueling efficiency, which current products may not yet meet.

In March 2024, the Ministry of Industry and Information Technology and three other departments released the “General Aviation Equipment Innovation Application Implementation Plan (2024-2030),” outlining targets for lithium battery development in related fields. The plan emphasizes accelerating the layout of new energy general aviation power technologies and equipment, promoting the mass production of 400Wh/kg aviation lithium batteries, and validating the application of 500Wh/kg aviation lithium battery products. Many industry experts believe that future improvements in battery performance will increasingly hinge on material innovations. Solid-state batteries, which combine high energy density and safety, may fundamentally resolve the energy constraints faced by eVTOLs.

In November 2024, EHang Intelligent announced the successful completion of the world’s first eVTOL flight test utilizing a solid-state battery, achieving a continuous flight time of 48 minutes and 10 seconds—an increase of 60% to 90% over previous durations. The solid-state battery was developed in collaboration with Xinjie Energy and the International Advanced Technology Application Center (Hefei) Low Altitude Economic Battery Energy Research Institute, achieving an energy density of 480Wh/kg, with mass production aimed for by the end of 2025. Additionally, traditional battery manufacturers such as CATL, EVE Energy, Guoxuan High-tech, and Funeng Technology have introduced semi-solid battery products while committing to solid-state battery research, viewing it as an ideal fit for eVTOL applications.

According to Guolian Securities, it is expected that after 2025, eVTOL batteries will gradually transition to semi-solid designs, with solid-state batteries potentially seeing significant production increases after 2030, greatly enhancing the operational radius of eVTOLs. As eVTOL commercialization progresses, flight frequency will dictate operational efficiency and project profitability, making the development of refueling infrastructure increasingly critical. EHang Intelligent has formed a strategic partnership with JuWan Technology to co-develop the world’s first ultra-fast charging battery solution for eVTOLs, focusing on building ultra-charging stations and related infrastructure. In parallel, EHang Intelligent and Guoxuan High-tech are prioritizing the development of high-power supercharging stations and energy storage systems as part of their collaboration.

In addition to fast charging, battery swapping represents another essential refueling strategy. The ZG-ONE “Que Fei” eVTOL product launched by Zero Gravity is designed for the cultural and tourism sector, enabling battery swaps within five minutes to cater to high-frequency transfer demands in tourist areas.

Currently, the standards for eVTOL battery products and infrastructure are still maturing, and the competitive landscape remains undefined. Industry players must collaborate with eVTOL manufacturers on joint research and development while partnering with leading firms to seize early advantages. Beyond R&D and market strategies, equity partnerships are also a vital means of enabling synergy across the eVTOL value chain. EHang Intelligent has already invested in Xinjie Energy, while in August 2024, Fengfei Aviation signed a strategic investment and cooperation agreement with CATL, which involved a substantial exclusive investment, positioning CATL as a strategic investor in Fengfei Aviation. Together, they will focus on the development of eVTOL aviation batteries.