The future of transportation is taking flight, and Joby Aviation is leading the charge. In a recent visit to their facilities, Sandy Munro and the Munro Live Team had the opportunity to explore the cutting-edge technology behind Joby's revolutionary electric vertical take-off and landing (eVTOL) aircraft. From the advanced composite manufacturing processes to the innovative powertrain and electronics systems, Joby is redefining the way we move around our cities.
The Dream Takes Flight
Joby Aviation's story began with a dream that founder and CEO JoeBen Bevirt had since his college days in the 1990s. "This was a dream of mine from when I was a kid to build a better way to get from A to B," Bevirt explained. At the time, the necessary battery technology was not yet ready, but as the years passed, advancements in lithium-ion batteries and electric motors paved the way for Bevirt's vision to become a reality.
Formally founded in 2009, Joby Aviation has since forged strategic partnerships with industry leaders like Delta Air Lines, the U.S. Department of Defense, Toyota, and Uber, solidifying its position as a frontrunner in the eVTOL market. With over a thousand different eVTOL concepts emerging worldwide, Bevirt likens the current state of the industry to the "Cambrian explosion" of early aviation in the 1900s, where entrepreneurs are exploring innovative ways to transform daily transportation.
Vertical Integration: The Key to Success
One of the key factors that sets Joby apart is its commitment to vertical integration. Rather than relying on outside suppliers for critical components, Joby has taken the bold step of designing and manufacturing its own motors, actuators, power electronics, and avionics systems in-house.
As Munro noted, "I've always been a fan of vertical integration. As soon as you hear someone say you have a 'core competency,' you know you're on the path to destruction." Joby's approach allows the company to optimize every system to work in perfect harmony, ensuring the highest levels of performance, safety, and efficiency.
Composite Manufacturing: Lightweight and Powerful
At the heart of Joby's aircraft are the advanced composite materials used in their construction. The manufacturing process begins with a robotic ply cutter that precisely cuts the carbon fiber prepreg sheets into the necessary components. These parts are then meticulously laid up by skilled technicians using automated fiber placement (AFP) robots, which dramatically reduce waste compared to traditional methods.
The resulting composite parts are then cured in Joby's impressive autoclave, a high-pressure and high-temperature oven that ensures the highest quality and consistency. Munro was particularly impressed by the size and scale of Joby's autoclave, noting that it was "a very big autoclave" and that the company would likely need "a bunch of autoclaves" to keep up with their production goals.
Powertrain and Electronics: The Heart of the Aircraft
Powering Joby's eVTOL aircraft is a highly integrated and optimized powertrain system, designed and built in-house by the company's talented engineering team. At the core of this system are the high-specific-torque motors, which can spin at just 250 RPM during cruise, a fraction of the speed of traditional aircraft propellers.
As John Wagner, Joby's Lead on Powertrain and Electronics, explained, this low-speed operation is a key factor in the aircraft's remarkably quiet acoustic profile. "When you're in cruise and it's flying over, you don't hear the propellers at all," he said. "You just hear a whoosh."
The motors are paired with custom-designed power electronics and cooling systems, all of which are housed in a compact, lightweight package. This modular approach not only enhances reliability and safety but also simplifies maintenance and repair.
Battery Technology: Powering the Future
At the heart of Joby's eVTOL aircraft are the advanced battery packs, which are also designed and manufactured in-house. Featuring a modular architecture, the battery system is divided into 28 individual modules, each housed in a titanium enclosure to ensure maximum safety and containment in the event of a failure.
As Wagner explained, the battery system's design is a critical aspect of Joby's commitment to safety. "We've made it so that we can withstand any kind of battery failure and maintain a safe continued flight and landing," he said. This level of redundancy and fail-safe engineering is essential for the FAA certification process and for instilling confidence in Joby's customers.
Testing and Validation: Ensuring Reliability
To ensure the reliability and performance of their eVTOL aircraft, Joby has invested heavily in a comprehensive testing and validation program. This includes a state-of-the-art dynamometer facility, where the company's propulsion systems are put through their paces, simulating real-world flight conditions and failure scenarios.
Joby's "iron bird" facility, located in Marina, California, takes this testing to the next level. Here, a full-scale mock-up of the aircraft is assembled, allowing the company to virtually fly the plane and test all of its systems in a controlled environment. This approach enables Joby to identify and address any issues long before the first flight, ensuring a smooth and successful development process.
Partnerships and Collaborations: Accelerating the Future
Joby's success is not just a result of its own technological prowess but also the strategic partnerships it has forged with industry leaders. As Bevirt mentioned, the company has collaborated with the likes of Delta Air Lines, the U.S. Department of Defense, Toyota, and Uber, each bringing unique expertise and resources to the table.
These partnerships are crucial for Joby as it works to build the necessary infrastructure and regulatory framework to bring its eVTOL aircraft to market. For example, the company is working with Delta to develop vertiport facilities at key hubs like JFK, LaGuardia, and LAX, ensuring a seamless integration between Joby's air mobility services and traditional air travel.
The Future of Urban Air Mobility
As Munro observed, Joby's eVTOL technology is arriving at a critical time, when the value of time has become more precious than ever. "Nobody can buy back a second for a billion dollars," he said, "and seconds count in today's world." Joby's vision of providing fast, efficient, and environmentally friendly air transportation within and between cities has the potential to revolutionize the way we move around our urban landscapes.
With its relentless focus on innovation, safety, and customer experience, Joby is poised to lead the charge in the burgeoning urban air mobility market. As the company continues to refine its technology and build the necessary infrastructure, the dream of a "Jetson-like" future may soon become a reality for people around the world.
As the future of transportation takes flight, Joby Aviation is leading the way with its innovative eVTOL technology and unwavering commitment to revolutionizing urban air mobility. With the support of industry-leading partners and the expertise of engineering visionaries like Sandy Munro, the dream of a more efficient, sustainable, and accessible transportation future is closer than ever before.