Butterfly eVTOL Prototype is Using Toray’s Carbon Fiber and Resin System

Photo by Soloman Soh on Pexels

Kimberly Hoodin

July 18, 2022

Overair selected Toray’s carbon fiber and resin system to develop the airframe structure and propulsion units for the Butterfly eVTOL (electric vertical take-off and landing) prototype program.

As traffic in densely populated urban areas continues to cause problems, including environmental and noise issues, interest and investment in electric vertical take-off and landing (eVTOL) aircraft grows.

Overair is partnering with Toray to develop the Butterfly eVTOL prototype aircraft, using Toray’s carbon fiber and resin system. The Butterfly will provide a zero-emission, low-noise sustainable ridesharing option and recently completed full-scale testing of the propulsion system.

Toray’s T1100/3960 prepreg system is formulated for high-performance aerospace applications where the optimal ratio of strength to modulus properties is critical and is being used in the Butterfly’s airframe structure and propulsion units. The 3960 cure epoxy resin allow for autoclave and out-of-autoclave curing and the TORAYCA™ T1100 carbon fiber offers exceptional tensile strength.

“We’re excited to be working closely with Toray’s advanced materials as we continue the development of our all-electric Butterfly experimental prototype aircraft,” said Ben Tigner, co-founder and CEO at Overair. “Our unique propulsion system requires materials that provide a unique combination of high stiffness and high strength, while also maintaining the optimal weight targets for the vehicle.”

Jeff Cross, director of business development for aerospace at Toray, added, “It is an honor for Toray to partner with Overair on this endeavor and provide the Butterfly a unique performance advantage with our 3960 prepreg system.” Mr. Cross continued, “We’re excited for the future as Overair proceeds with full-scale development and testing. The proven performance of our materials gives me confidence that we can help achieve Overair’s objective of producing the safest, most efficient, and reliable eVTOL aircraft.”

The Butterfly will feature a 100+ mile range with a cruise speed of up to 200 miles per hour and zero emissions from its fully electric powertrain. Safety testing indicates no single-point failures.

The Butterfly is expected to take flight in 2023.

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