MagLev Aero

MagLev Aero addresses the limitations of conventional shaft-based rotor systems used in helicopters and multi-rotor eVTOLs, which are restricted in their ability to utilize their full span and swept area. This results in significant noise and efficiency losses. Additionally, conventional rolling supports for large-diameter rotors are limited to low speeds and short service lives due to high centrifugal loading.

In aviation, power is a "fairly expensive commodity," and current systems struggle to balance high thrust with the need for sustainability and noise reduction.

The startup's breakthrough is the MagLev HyperDrive™, a magnetically levitated electric propulsion system.

Unlike traditional engines, it uses a mag-electric rim drive around the outside of the propeller, which allows for more efficient flow acceleration through the rotor system. This technology leverages the frictionless advantages of maglev trains for aviation, using a fault-tolerant motor-bearing system to support a slowed, rim-driven rotor.

This design eliminates conventional blade-tip clearance losses, a significant source of aerodynamic inefficiency and noise, by directly driving and supporting the rotor at its perimeter.

MagLev Aero is advancing high-performance electric aviation with a clean, ultra-quiet propulsion system aligned with key Sustainable Development Goals.

Its technology cuts noise drastically around 1/100th of traditional systems roughly 20 dBA quieter than helicopters, making cities more livable (SDG 11). At the same time, comparative studies have demonstrated up to 48% more thrust at the same power, with the potential for substantial payload or range advantages depending on the aircraft and mission, improving energy efficiency (SDG 7).

This breakthrough in electric propulsion pushes forward aerospace innovation (SDG 9) while unlocking high-impact use cases like medical logistics. By reducing noise and energy consumption, it also supports climate action through cleaner aviation (SDG 13).

MagLev Aero views itself as a "living demonstration" of the 3DEXPERIENCE vision, utilizing it as a unified digital thread at the heart of their development.

They use the platform to manage the entire product lifecycle, from initial design and ideation through build, test, and eventually into the customer's hands. This enables a unified customer experience and provides deep insight into system performance.

The company has used Dassault Systèmes' tools such as SolidWorks since its inception as a design-build-fly competition entry.

The company leverages collective intelligence by assembling a multidisciplinary team of scientists, engineers, builders, and professionals specializing in aerodynamics, aeromechanics, aeroacoustics, and electrodynamics. They foster collaboration through:

• Internal Expertise: In-house specialists work directly with customer design teams to tailor thruster systems and maximize vehicle performance.
• Strategic Partnerships: Supported by investors such as Breakthrough Energy Ventures and collaborations with aerospace firms including Transcend Air and XTI Aerospace to explore uncrewed and tiltwing aircraft applications.
• Integrated Design: A unified digital thread ensures all team members have the necessary insight to contribute to the propulsion breakthrough.