How to Choose Manned Drone Motors:3 models for Your needs

In the rapidly developing landscape of Urban Air Mobility(UAM),electric Vertical Take-Off and Landing(eVTOL)aircraft,and the broader low-altitude economy,the strategic importance of motors for manned drones has become increasingly prominent.These motors are not just the power source that lifts the aircraft but are also a core element influencing safety,the airworthiness certification process,and operational costs.

For enterprise users,the selection of a motor is not merely a procurement decision;it is a systemic task closely intertwined with project architecture design,certification compliance,full lifecycle management,and supply chain security.Inadequate motor performance or improper selection can lead to flight test failures,delays in obtaining airworthiness certification,and even directly impact the return on investment(ROI).

This article will cover the technical principles of motors and combine industry applications with business value to help stakeholders make efficient,compliant,and sustainable selection decisions.

I. Fundamentals of Manned Drone Motors

1. The Core Role of Motors in Manned Drones

The motor is the core power component of a manned drone,analogous to its"heart."It is responsible for converting electrical energy into thrust,which not only determines whether the aircraft can take off,hover,and land smoothly but also directly affects flight safety,energy efficiency,and noise control.For enterprise users,the quality of motor performance impacts the entire project's feasibility and commercial viability:

High Dependence on Flight Performance:

The magnitude and response speed of the motor's thrust determine the aircraft's payload capacity,climb rate,and wind resistance.

Indispensable Safety Redundancy:

In manned scenarios,the tolerance for motor failure is extremely low.Therefore,system design must incorporate a multi-motor redundant architecture to ensure safe flight even if a single motor fails.

Energy Efficiency and Economics:

Higher motor efficiency means lower energy loss,which can significantly extend flight endurance and reduce operational costs.

Airworthiness and Compliance:

Motors must comply with airworthiness standards from bodies like the FAA,EASA,and the Civil Aviation Administration of China(CAAC),covering material strength,redundant design,lifecycle testing,and electromagnetic compatibility.

2. Enterprise vs Consumer Manned Drone Motors

While the operating principles of manned drone motors are similar to those of consumer drones,there are fundamental differences in performance metrics,reliability requirements,and certification standards:

Thrust Level:

Consumer-grade motors typically produce a few kilograms to tens of kilograms of thrust,whereas a single motor for a manned drone often needs to deliver≥90–120 kg of thrust.

Redundancy Requirements:

Consumer drones can tolerate a certain level of risk,while manned drones must adopt an N+1 redundant design to ensure that a single point of failure does not lead to a crash.

Lifespan and Durability:

Consumer motors are designed for short-term use,with a lifespan of around a few hundred hours.Enterprise-grade motors must pass fatigue tests to meet the demands of commercial operation.

Compliance:

Consumer products do not require airworthiness certification,whereas enterprise-grade motors must meet the airworthiness requirements of agencies like the FAA,EASA,and CAAC,including verification of noise,vibration,and electromagnetic compatibility.

II. Types and Technical Comparison of Manned Drone Motors

In the field of manned drones,the three most common types of motors are the Brushless DC Motor(BLDC),the Permanent Magnet Synchronous Motor(PMSM),and the Axial Flux Motor(AFM).Each type has distinct advantages in terms of structural principle,power density,efficiency,cost,and application scenarios.

When making a selection,companies need to conduct a comprehensive assessment based on project scale,flight scenarios,certification requirements,and budget.

1. Brushless DC Motor(BLDC)

1.1 Technical Principle:

BLDC motors use electronic commutation instead of the mechanical commutation found in traditional brushed motors.They are typically driven by a square wave,with a permanent magnet rotor and wound stator.Their biggest advantage is a simple structure,low cost,and minimal maintenance.

1.2 Features and Pros&Cons:

Pros:Relatively high efficiency(85–90%),mature manufacturing processes,low price,and suitability for mass production.

Cons:Limited power density,higher noise levels,and less smooth operation compared to sine wave-driven motors.

Suitability:Better suited for small to medium-sized drones and industrial multi-rotors.They struggle to meet the high thrust and redundancy requirements of large manned aircraft.

1.3 Typical Applications:

Industrial drones,logistics drones,and Vertical Take-Off and Landing(VTOL)drones with low to medium payloads.

2. Permanent Magnet Synchronous Motor(PMSM)

2.1 Technical Principle:

PMSM motors use rare-earth magnetic materials(like Neodymium Iron Boron,NdFeB)for the rotor's permanent magnets.The stator windings create a rotating magnetic field when energized.Driven by a sine wave and combined with Field-Oriented Control(FOC)technology,they achieve smooth rotation with high efficiency and precise speed control.

2.2 Features and Pros&Cons:

Pros:Extremely high efficiency(92–95%),high power density,stable torque output,and support for a wide speed range.

Cons:Higher cost,dependence on rare-earth materials,and complex manufacturing and control technology.

Suitability:The current mainstream choice for eVTOL and UAM projects,validated in multiple manned aircraft flight tests.

2.3 Typical Applications:

Urban Air Mobility(UAM)aircraft,electric helicopters and eVTOL prototypes,and high-payload,long-endurance drones.

3. Axial Flux Motor(AFM)

3.1 Technical Principle:

Unlike the radial flux design of traditional motors,AFM motors use an axial magnetic field.This results in a shorter magnetic path,a more compact size,and higher power density.For the same power output,weight can be reduced by 20–30%,and efficiency can be improved by 3–5%.

3.2 Features and Pros&Cons:

Pros:Over 30%higher power density than traditional motors,significant weight reduction,excellent heat dissipation,and extremely low noise.This makes them especially suitable for noise-sensitive scenarios like urban air mobility.

Cons:Complex manufacturing processes,high cost,and currently less industrialized than PMSM.

Suitability:Better suited for future high-end electric aircraft and long-range manned vehicles.It is a key direction for next-generation UAM technology.

3.3 Typical Applications:

Electric airplanes,high-end eVTOL prototypes,and aviation scenarios with stringent requirements for energy efficiency and lightweight design.

Comparison of Three Motor Types：

III.Industry Applications and Business Value of Manned Drone Motors

Manned drone motors are not just the power source for aircraft;they are a key pillar supporting the development of the low-altitude economy.

Different application scenarios have varying performance requirements for motors,but they all share an emphasis on safety,redundancy,energy efficiency,and compliance.The following core areas have become key markets for businesses and investors.

1. Urban Air Mobility(UAM)

1.1 Industry Background:

Urban congestion is a growing problem worldwide.Traditional ground transportation is nearing its capacity and efficiency limits.UAM is considered one of the most disruptive modes of travel for the next decade.According to a forecast by Morgan Stanley,the global UAM market could exceed$1 trillion by 2035.

1.2 Motor Requirement Characteristics:

Low Noise:Urban residents are sensitive to noise,so motors require low-vibration and low-harmonic designs.

High Reliability:A failure during flight over a city would have severe consequences,requiring motors to have a redundant architecture(e.g.,N+1 design).

Long Lifespan:With high daily operational frequency,motors must pass fatigue tests for a cumulative life of at least 1,000 hours to support long-term commercial operations.

Compliance:Must meet FAA/EASA airworthiness standards and relevant low-altitude flight regulations from the CAAC.

1.3 Business Value:

Alleviates ground traffic pressure and shortens commute times.

Supports green transportation,aligning with urban low-carbon development strategies.

Represents an emerging market for aerospace and technology companies to compete in.

1.4 Typical Cases:

Joby Aviation:Uses Permanent Magnet Synchronous Motors(PMSM),focusing on noise reduction and efficiency.

EHang:Conducts UAM pilot flights in China,where motor safety has become a core indicator for airworthiness approval.

2. Emergency Medical Services(EMS)and Public Safety

2.1 Industry Background:

In cases of sudden illness,natural disasters,or accident rescue,time often determines life or death.Traditional ambulances are limited by road conditions,while helicopters are noisy and have high operating costs.Manned drones offer a new,efficient,and flexible emergency response solution.

2.2 Motor Requirement Characteristics:

High Thrust and Fast Response:Must carry medical personnel,equipment,and patients,requiring single-motor thrust of≥100 kg.

Reliability:Stable operation even in adverse weather conditions.

Endurance and Efficiency:A flight time of over 30 minutes is necessary to support rapid long-distance rescue.

Redundant Design:To prevent rescue interruptions due to a single point of failure.

2.3 Business Value:

Enhances public safety and medical system capabilities.

Receives government policy and financial support.

Deeply integrates with urban public service systems,creating stable demand.

2.4 Typical Cases:

Germany:Proposed using eVTOLs for emergency ambulance scenarios.

China:Already experimenting with drone motor systems for emergency supply transport and casualty evacuation tests.

3. Tourism and Commercial Services

3.1 Industry Background:

As the tourism industry evolves,low-altitude sightseeing is becoming a differentiating competitive advantage.Compared to traditional helicopters,manned drones offer lower noise,are more environmentally friendly,and have lower operating costs.

3.2 Motor Requirement Characteristics:

Quiet Operation:To minimize disruption to the tourist experience and the environment.

Lightweight:The lower the motor's weight,the more passengers it can carry or the longer its endurance.

High Reliability:Commercial operations involve high frequency,imposing strict requirements on motor lifespan and maintenance cycles.

3.3 Business Value:

Creates new tourism experiences and enhances the attractiveness of scenic areas.

Reduces operator costs(over 30%more energy-efficient than traditional helicopters).

Establishes a stable ticketing revenue model with a relatively high return on investment.

3.4 Typical Cases:

Dubai Pilot Project:Using manned drones for city sightseeing tours.

Hainan Sanya,Zhangjiajie,and other locations in China:Scenic areas are exploring pilot operations of low-altitude sightseeing drones.

IV.Key Considerations for Manned Drone Motor Selection

Selecting a motor for a manned drone is different from choosing one for a consumer drone.It's not enough for it to"just work."A systematic evaluation is required across multiple factors,including thrust-to-weight ratio,safety redundancy,KV value matching,material reliability,and airworthiness certification.

For an enterprise,the right motor choice can significantly reduce R&D risks,shorten the airworthiness certification cycle,and optimize the full lifecycle ROI after commercial deployment.The following five points are critical for enterprises to focus on during motor selection.

1. Thrust-to-Weight Ratio(TWR)and Redundant Design

The Thrust-to-Weight Ratio(TWR)is the primary indicator of an aircraft's power reserve.

Formula:TWR=Total Thrust÷Gross Takeoff Weight

1.1 Selection Criteria:

Minimum Requirement:TWR≥2.0(thrust is at least twice the weight).

Recommended Range:TWR=2.5–3.0(suitable for manned flight,ensuring a safety margin in emergencies).

Extreme Scenarios(adverse weather,rescue missions):TWR≥3.0.

1.2 Redundant Design:

N+1 Architecture:Ensures that if one motor fails,the remaining motors can still provide enough thrust to maintain flight.

For an 8-rotor manned drone,the design must ensure that after a single motor failure,the remaining motors can sustain sufficient thrust for safe flight.

Multi-Motor Layouts:6-rotor,8-rotor,and symmetrical coaxial layouts are common redundancy solutions.

Example:A 250 kg manned drone with a total weight(airframe+battery+occupant+payload)of 250 kg.

If using 8 motors,each motor must produce≥80kg of thrust.

A 15%redundancy margin should be included,meaning the optimal thrust per motor should be≥92kg.

2. KV Rating and Propeller Matching

The KV rating(RPM/V)indicates the motor's rotational speed per volt of applied voltage.

2.1 Difference Between High and Low KV:

Low KV(29–43 KV):Low speed,high torque.Suitable for driving large-diameter propellers to produce sustained high thrust.

High KV:High speed,low torque.Suitable for small drones,not for manned aircraft.

2.2 Matching Logic:

Large-diameter propellers(22–26 inches)+Low KV motors(29–38 KV).

Extra-large propellers(26–32 inches)+Even lower KV motors(~29 KV).

2.3 Examples:

U15L KV43 paired with a 47x18 propeller can produce single-prop thrust of≥90kg.

U15XXL KV29 paired with a 62x24 propeller can produce single-prop thrust of≥120kg.

3. Material Reliability and Thermal Design

3.1 Motor Housing and Structure:

Use 7075-T6 aviation-grade aluminum for high strength,fatigue resistance,and good thermal performance.

Should pass MIL-STD-810G vibration tests to ensure stability in complex airflow and during long flights.

3.2 Windings and Magnets:

Winding insulation must meet the UL1446 thermal class standard(≥200°C).

Neodymium Iron Boron(NdFeB)magnets are recommended for the rotor to ensure high magnetic density and long life.

3.3 Cooling Methods:

Air Cooling:Suitable for low-to-medium power motors.

Liquid Cooling:For continuous current≥100A,liquid cooling can control temperature rise to≤40°C,significantly improving stability.

3.4 Value Proposition for Enterprises:

High-reliability materials and efficient cooling reduce failure rates.

Long lifespan and low maintenance frequency lower operational costs and improve ROI.

4.Safety and Certification Requirements

4.1 Airworthiness certification for manned drones imposes strict requirements on the propulsion system:

FAA/EASA Redundancy Requirements:The propulsion system must be single-fault tolerant.

Structure and Loads:Must comply with CAAC special conditions and the aircraft's load spectrum(including ultimate/destructive loads and safety margins),primarily verified through g-load factor and spectrum tests.

Electromagnetic Compatibility(EMI/EMC):Implementation and certification must follow the relevant sections of RTCA DO-160.

4.2 Testing Standards:

Fatigue Life:Motor assembly and environmental durability testing according to DO-160 and project specifications.Composite material propeller blades can reference standards like ASTM D3479 for material fatigue.

Vibration and Shock Resistance:MIL-STD-810G.

4.3 Significance:

For enterprises,choosing motors that have already passed relevant certifications or have certification potential can drastically shorten the airworthiness timeline,avoiding repetitive testing and additional costs.

5. Supply Chain and ROI Considerations

5.1 Supply Chain Security:

Enterprise-level projects must ensure the motor's batch delivery capability and long-term supply.It is recommended to choose suppliers with scalable production capacity(e.g.,T-Motor,Maxon,Emrax)to avoid the risk of discontinuation.

5.2 Return on Investment(ROI):

Investment:Costs of motor procurement,testing and validation,and airworthiness certification.

Return:Higher safety,faster certification progress,and lower operational costs.

The key to optimizing ROI is to reduce project delays and extra expenses caused by trial and error.

V.Manned Drone Motor Solutions and Model Recommendations

For enterprise users,motor selection is not just about purchasing a specific model but requires considering a complete system solution.A comprehensive manned drone propulsion system typically includes the motor,Electronic Speed Controller(ESC),and propeller,all of which have undergone full lifecycle testing and airworthiness validation.

By using a packaged solution,enterprises can:

Shorten the R&D cycle and reduce trial-and-error costs.

Improve system compatibility and reduce the risk of incompatibility between the motor,propeller,and ESC.

Facilitate airworthiness certification,as the entire system has already been validated.

Below are recommended configurations for enterprise-level projects,combining typical solutions and models.

1. Solution A:Light-Payload eVTOL Motor System

Motor:T-motor U15L KV43

ESC:T-motor Thunder 300A 24S ESC

Propeller:T-motor NS47*18 Carbon Fiber Propeller

Single-Prop Thrust:≥90kg

Application Scenarios:Light-payload eVTOLs,short-range sightseeing,entry-level urban commuting.

2. Solution B:Medium-Payload UAM Commuter Motor Kit

Motor:T-motor U15XL KV38

ESC:T-motorThunder 300A 24S ESC

Propeller:T-motor NS52*20 Carbon Fiber Propeller

Single-Prop Thrust:≥100kg

Application Scenarios:Mainstream UAM commuter aircraft,medium-range manned drones.

3. Solution C:Heavy-Payload and Long-Endurance Drone Motor Kit

Motor:T-motor U15XXL KV29

ESC:T-motor Thunder 300A 24S ESC

Propeller:T-motor NS57*22/T-motor NS62*24 Carbon Fiber Propeller

Single-Prop Thrust:≥120kg

Application Scenarios:Heavy-payload cargo drones,long-endurance emergency medical eVTOLs.

VI. Conclusion

As manned drones move toward commercialization,the motor is not only the power core but also a decisive factor for R&D success,airworthiness certification,and large-scale operations.For enterprises,motor selection affects safety,certification timelines,maintenance costs,and overall ROI.

With applications such as urban air mobility,emergency rescue and tourism emerging,motor requirements for reliability and performance will keep rising.Enterprises that adopt validated,lifecycle-supported,and customizable motor solutions will be best positioned to stay competitive and achieve sustainable commercialization.