Horizon Aircraft Reaches Key Milestone in Hybrid-eVTOL Development

The race toward next-generation air mobility has taken a significant turn as Horizon Aircraft, a Canadian aerospace innovator, successfully completed full transition flight testing with its scaled Cavorite X5 demonstrator. This achievement marks a pivotal validation of the company’s hybrid-electric vertical takeoff and landing (eVTOL) architecture, setting the stage for the development of its full-scale Cavorite X7 prototype.

As the global aviation industry seeks sustainable alternatives to conventional aircraft, hybrid-eVTOLs present a promising middle ground. They combine the vertical agility of helicopters with the efficiency of fixed-wing aircraft. Horizon’s approach, which blends electric lift with a thermally driven cruise system, offers a pragmatic pathway toward decarbonized regional aviation without the infrastructure burdens of all-electric models.

Technical Foundations and Flight Transition Milestone

The Cavorite X5 demonstrator, a subscale version of the envisioned X7 aircraft, features a 6.7-meter wingspan and a 272 kg maximum takeoff weight. Its hybrid propulsion system incorporates 16 electric ducted fans—10 embedded within the wings and six in forward canards. These are covered by sliding panels that retract during vertical lift and close during forward flight, allowing the aircraft to transition into a low-drag, wing-borne configuration.

In recent flight tests, Horizon achieved a full transition to forward flight, with the fan covers completely closed mid-air. According to CEO Brandon Robinson, the maneuver was so seamless it was described as “a non-event,” with the only surprise being the aircraft’s rapid acceleration once the panels sealed. This smooth transition validates the aerodynamic and propulsion principles behind the X7’s design.

The successful test flights began in April 2024 and culminated in a fully autonomous transition maneuver by May. This milestone confirms the feasibility of Horizon’s hybrid approach and de-risks the design of the full-scale X7, which shares 85% of its aerodynamic profile with the X5.

“Flying most of the mission as a normal aircraft is safer, more efficient, and will be easier to certify than radical new eVTOL designs. The X5’s performance validates our physics-driven approach.” Brandon Robinson, CEO, Horizon Aircraft

Design and Development of the Cavorite X7

The full-scale Cavorite X7 is designed to carry up to six passengers and boasts a wingspan of 15 meters with a gross takeoff weight of 2,500 kg. It is expected to deliver a range of up to 800 km at cruising speeds of 450 km/h, significantly outpacing current all-electric eVTOL competitors in both range and payload capacity.

Unlike many of its peers, the X7 will use a rear-mounted Pratt & Whitney Canada PT6A engine to power the cruise propeller and charge onboard batteries. Horizon is currently evaluating the -135 and -140 variants of the PT6A, though no formal supplier agreement has been finalized. Initial test flights, planned for 2027, will likely take place in a conventional takeoff and landing (CTOL) configuration before integrating the full vertical lift system.

Component and systems-level testing is already underway at Horizon’s facility in Lindsay, Ontario. A detailed design review is scheduled soon, with ground testing of the full-scale prototype expected within 18 to 24 months. This timeline aligns with the company’s target of a maiden X7 flight by late 2027.

Strategic Funding and Market Positioning

To support its development roadmap, Horizon secured USD 8.4 million in early 2025 through a mix of equity and convertible preferred stock. This funding round provides sufficient capital for the next 12–18 months, though the company continues to explore additional investment opportunities to extend its financial runway.

Horizon has also joined the U.S. Air Force‘s AFWERX High-Speed VTOL (HSVTOL) Challenge, positioning the X7 for military applications such as medevac, cargo transport, and reconnaissance. With a projected 100 kW of excess power and a top speed of 250 knots, the aircraft is well-suited for non-civilian missions where charging infrastructure is limited or unavailable.

Industry analysts suggest that Horizon’s focus on logistics and defense markets provides a strategic advantage. These sectors face fewer regulatory hurdles than urban air taxi services and offer immediate revenue streams, allowing the company to refine its technology before entering the more complex passenger transport space.

“The X7’s 100 kW excess power capacity and 250-knot speed make it ideal for reconnaissance and rapid deployment. Its hybrid system eliminates dependency on charging infrastructure—a game-changer for frontline operations.” Kelly Murphy, Military Applications Lead

Certification and Regulatory Landscape

Horizon’s development timeline coincides with evolving regulatory frameworks for advanced air mobility. The FAA’s 2024 Special Federal Aviation Regulation (SFAR) for eVTOLs classifies such aircraft under a hybrid model: helicopter rules for takeoff and landing, and airplane standards for cruise flight. This hybrid classification suits the Cavorite X7’s operational profile.

Additionally, harmonization efforts between the FAA and EASA have raised the maximum takeoff mass for eVTOL certification to 5,700 kg, accommodating larger hybrid models like the X7. These regulatory adjustments are critical enablers for Horizon’s certification path and eventual commercial deployment.

While the dual propulsion system introduces added complexity to the certification process, Horizon’s decision to prioritize CTOL testing initially may streamline early approval phases. This phased approach allows the company to gather performance data incrementally while working toward full VTOL certification.

Conclusion: A Promising Future for Hybrid-eVTOLs

The successful transition flight of the Cavorite X5 is more than a technical milestone—it’s a validation of Horizon Aircraft’s strategic vision. By focusing on hybrid-electric propulsion and targeting markets with immediate utility, the company is carving out a distinct niche in the advanced air mobility ecosystem. The X7, with its extended range and payload capabilities, is poised to serve roles where all-electric models fall short.

As Horizon advances toward a 2027 prototype flight, its disciplined, physics-based approach offers a refreshing counterpoint to the hype-driven narratives surrounding eVTOLs. If the company can maintain its momentum and secure the necessary funding and regulatory approvals, the Cavorite X7 may well redefine what’s possible in regional aviation by the end of the decade.

FAQ

What is the Cavorite X5?
The Cavorite X5 is a scaled demonstrator aircraft developed by Horizon Aircraft to test and validate its hybrid-eVTOL technology. It features a 6.7-meter wingspan and a 272 kg maximum takeoff weight.

When will the full-scale Cavorite X7 fly?
Horizon Aircraft aims to conduct the first flight of the full-scale Cavorite X7 in 2027, initially in a conventional takeoff and landing configuration.

What makes Horizon’s eVTOL different from others?
Unlike fully electric eVTOLs, Horizon’s hybrid approach uses a thermal engine for cruise and battery-powered fans for vertical lift, offering longer range and greater payload capacity without relying on charging infrastructure.

Sources: FlightGlobal, eVTOL Insights, eVTOL News, AeroTime, Vertical Magazine

Klein Vision’s AirCar: The Future of Dual-Mode Personal Mobility

After more than three decades of development, Klein Vision has officially unveiled the production prototype of its AirCar, a certified flying car that merges automotive and aviation engineering into a single, road-and-air-capable vehicle. The announcement took place at the 2025 Living Legends of Aviation Gala, where founder Stefan Klein was honored with the Special Recognition Award for Engineering Excellence. The AirCar represents a significant milestone in the evolution of personal transportation, promising to reshape mobility paradigms for years to come.

The AirCar is not just a concept or experimental prototype, it’s a certified aircraft with over 500 successful test flights and more than 170 flight hours logged. Its ability to transition from a car to an aircraft in under two minutes sets it apart from previous attempts in the field. As the world grapples with urban congestion and the need for more flexible transport options, the AirCar enters the scene as a viable solution, combining the convenience of road travel with the speed and freedom of flight.

Engineering and Technical Innovation

Dual-Mode Design and Transformation

The AirCar’s standout feature is its seamless transformation from a road vehicle to an aircraft. This process is completed in under 80 seconds through a system of over 20 programmable servo motors that deploy the wings, extend the tail boom, and reconfigure the drivetrain. The steering wheel converts into a yoke for flight control, and the pedal system adjusts for rudder input, allowing intuitive operation in both modes.

Constructed with a carbon-fiber-reinforced monocoque chassis, the AirCar achieves a balance between lightweight agility and structural integrity. This design not only enhances aerodynamic efficiency but also meets both EU road safety standards and EASA CS-23 aviation certification requirements. The use of advanced composite materials further reduces weight while maintaining durability under both driving and flying conditions.

Its 27-foot wingspan, when deployed, provides the necessary lift for stable flight, while its compact form when retracted allows it to operate on standard roads and fit into conventional parking spaces. This level of integration is rare among dual-mode vehicles and marks a significant leap in engineering design.

“The freedom of flight should be accessible, not confined to pilots or airports.” — Stefan Klein, Founder of Klein Vision

Powertrain and Performance

The AirCar is powered by a 1.6L BMW engine delivering 140 HP, enabling it to cruise at an airspeed of 170 km/h (105 mph) and reach a top road speed of 200 km/h (124 mph). The vehicle’s fuel system includes three tanks with a total capacity of 160 liters, enabling a flight range of 1,000 km (620 miles) and a road range of 800 km (497 miles).

In terms of safety, the AirCar includes a ballistic parachute system and adheres to rigorous aviation standards. Certification under FAA Part 23 is expected by late 2025, clearing the path for international operations. These features position the AirCar as not only a technological marvel but also a safe and reliable mode of transport.

By leveraging existing infrastructure, airports and roadways, the AirCar avoids the deployment challenges faced by electric VTOLs (eVTOLs), which require vertiports and new regulatory frameworks. This compatibility with current systems may accelerate its adoption in both urban and regional settings.

       AirCar production prototype

Market Positioning and Strategic Outlook

Commercial Debut and Pricing

The AirCar’s production prototype was unveiled to the public during an emotional presentation at the Living Legends of Aviation Gala, accompanied by a documentary chronicling Stefan Klein’s 35-year journey. The event emphasized the vehicle’s transition from prototype to market-ready product, with customer deliveries anticipated in early 2026.

Targeting affluent early adopters, the AirCar is expected to retail between $800,000 and $1 million. While this price point limits mass-market accessibility, it positions the AirCar as a luxury mobility solution for high-net-worth individuals and niche commercial applications. Potential use cases include inter-city travel, executive transport, and even emergency response in remote areas.

Klein Vision is actively seeking partnerships with aerospace suppliers and urban mobility networks to scale production and distribution. These collaborations aim to streamline supply chains, reduce costs, and expand the vehicle’s reach across international markets.

Future Variants and Expansion

In addition to the standard model, Klein Vision has announced plans for an amphibious version of the AirCar capable of water landings. This variant would expand the vehicle’s utility in island nations, coastal cities, and regions with limited road infrastructure. Such adaptability could make the AirCar a valuable asset in disaster relief and maritime logistics.

Long-term development includes hybrid-electric models aimed at reducing the vehicle’s carbon footprint. While the current gasoline-powered engine offers extended range and infrastructure compatibility, future iterations may incorporate sustainable technologies to align with global decarbonization goals.

As the urban air mobility (UAM) sector continues to grow, projected to reach $162 billion by 2034, the AirCar’s early certification and operational readiness give it a competitive edge. Unlike many competitors still in the conceptual or testing phase, Klein Vision’s offering is poised for real-world deployment.

Challenges and Industry Implications

Regulatory and Infrastructure Barriers

Despite its certification in Slovakia, the AirCar faces significant regulatory hurdles in other jurisdictions. Harmonizing air-traffic management systems and establishing protocols for dual-mode vehicles will require international cooperation and legislative innovation. The complexity of integrating flying cars into existing airspace remains a formidable challenge.

Additionally, the AirCar’s reliance on runways for takeoff and landing limits its urban applicability compared to eVTOLs, which are designed for vertical operations. This constraint may restrict its use to regions with accessible airstrips unless new infrastructure is developed to accommodate such vehicles.

Public perception and acceptance also play a crucial role. While the AirCar’s safety features and certification offer reassurance, widespread adoption will depend on education, demonstration, and trust-building among consumers and regulators alike.

Economic and Environmental Considerations

At nearly $1 million per unit, the AirCar is not yet a mass-market solution. Its high cost reflects the complexity of its engineering and the early stage of its production lifecycle. Economies of scale and technological advances may eventually lower prices, but for now, the AirCar remains a premium product.

Environmental concerns also persist. The current model runs on gasoline, which contrasts with the shift toward electrification in the broader mobility sector. Klein Vision has acknowledged this gap and plans to introduce hybrid-electric variants post-2030, aligning with global sustainability efforts.

Nonetheless, the AirCar’s ability to leverage existing infrastructure and its progress in certification set it apart in a crowded and often speculative field. Its development offers valuable insights into the challenges and opportunities of integrating air and ground mobility.

Conclusion: A New Dimension in Personal Transport

The Klein Vision AirCar is more than a technological novelty, it’s a certified, operational vehicle that redefines the boundaries between road and sky. With its production prototype now unveiled and customer deliveries on the horizon, the AirCar marks a pivotal moment in the history of personal mobility. Its blend of engineering excellence, regulatory compliance, and visionary leadership positions it as a trailblazer in the emerging dual-mode transportation sector.

Looking ahead, the AirCar’s success will depend on its ability to navigate regulatory landscapes, scale production, and adapt to environmental demands. As Stefan Klein and his team continue to innovate, the dream of accessible, airborne personal travel moves closer to reality. Whether as a luxury vehicle, a practical tool, or a symbol of human ingenuity, the AirCar is undeniably propelling us into a new era of movement.

FAQ

What is the top speed of the AirCar?
The AirCar can reach a cruising airspeed of 170 km/h (105 mph) and a top road speed of 200 km/h (124 mph).

How long does it take to transform from car to aircraft?
The transformation process takes approximately 80 seconds and is fully automated using servo motors.

When will the AirCar be available for purchase?
Customer deliveries are expected to begin in early 2026, following certification under FAA Part 23.

Sources:

• Military Aerospace
• New Atlas, Klein Vision

Ancient Pterosaur Bones May Revolutionize Aerospace

The study of ancient pterosaur bones could hold the key to developing lighter, stronger materials for the next generation of aircraft. Recent research from The University of Manchester has revealed that the microarchitecture of these prehistoric flying reptiles’ bones contains a complex network of tiny canals, making them both lightweight and incredibly strong. This discovery could lead to a ‘palaeo-biomimetics’ revolution, where biological designs from extinct species inspire modern engineering solutions.

Pterosaurs, close relatives of dinosaurs, were the first vertebrates to achieve powered flight. With wingspans ranging from 2 meters to over 10 meters, these creatures faced significant engineering challenges to support their massive wings. The findings, published in Nature’s Scientific Reports, suggest that the unique structures in their bones could inspire new materials for the aerospace industry, potentially reducing fuel consumption and improving safety.

This research highlights the importance of looking to nature—and even extinct species—for innovative solutions. As the aerospace industry continues to seek stronger, lighter, and more efficient materials, pterosaurs may provide the blueprint for the future of flight.

The Microarchitecture of Pterosaur Bones

Using advanced X-ray Computed Tomography (XCT), scientists scanned fossilized pterosaur bones at near sub-micrometer resolution, revealing structures approximately 20 times smaller than the width of a human hair. These scans uncovered a complex network of tiny canals and pores that were originally used for nutrient transfer, growth, and maintenance in the living creatures.

These structures also serve a mechanical function, deflecting cracks and protecting against microfractures. This dual biological and mechanical role makes pterosaur bones an ideal model for developing lightweight, strong materials. The researchers believe that replicating these natural designs could lead to significant advancements in aircraft construction.

Nathan Pili, the study’s lead author, emphasized the potential of this discovery: “We hope one day we can use these structures to reduce the weight of aircraft materials, thereby reducing fuel consumption and potentially making planes safer.”

“For centuries, engineers have looked to nature for inspiration—like how the burrs from plants led to the invention of Velcro. But we rarely look back to extinct species when seeking inspiration for new engineering developments—but we should.” – Nathan Pili, Ph.D. Student at The University of Manchester

Applications in Modern Aerospace

The aerospace industry is constantly striving for materials that are stronger, lighter, and more efficient. The microarchitecture of pterosaur bones aligns perfectly with these goals. By replicating these natural designs, engineers could create components that not only reduce weight but also incorporate sensors and self-healing materials.

Advancements in metal 3D printing could turn these ideas into reality, allowing for the creation of complex structures inspired by pterosaur bones. This could lead to more efficient aircraft designs, reducing fuel consumption and environmental impact while improving safety standards.

Professor Phil Manning, a senior author of the study, highlighted the broader implications: “There is over four billion years of experimental design that were a function of Darwinian natural selection. We hope to unlock the potential of ancient natural solutions to create new materials but also help build a more sustainable future.”

Challenges and Future Directions

While the potential applications are exciting, there are challenges to overcome. Replicating the microarchitecture of pterosaur bones at scale requires advanced manufacturing techniques and materials. Additionally, integrating these designs into existing aircraft structures will require extensive testing and validation.

Future research will focus on scanning additional extinct species to uncover more hidden engineering solutions. The team is also exploring ways to optimize these designs for practical applications, ensuring they meet the rigorous standards of the aerospace industry.

As the field of palaeo-biomimetics grows, it could open up new possibilities for innovation across various industries, from aviation to robotics and beyond.

Conclusion

The study of pterosaur bones has revealed remarkable insights into the natural engineering solutions that evolved over millions of years. These ancient adaptations could revolutionize the aerospace industry, leading to lighter, stronger, and more efficient materials. By looking back to extinct species, scientists and engineers are paving the way for the next generation of aviation technology.

As research continues, the potential applications of these findings could extend far beyond aerospace, offering sustainable solutions for a wide range of industries. The future of engineering may well be shaped by the lessons of the past.

FAQ

What are pterosaurs?
Pterosaurs were flying reptiles that lived during the Mesozoic era and were the first vertebrates to achieve powered flight.

How could pterosaur bones impact aerospace?
The microarchitecture of pterosaur bones could inspire the development of lighter, stronger materials for aircraft, reducing fuel consumption and improving safety.

What is palaeo-biomimetics?
Palaeo-biomimetics is the study of using biological designs from extinct species to inspire modern engineering solutions.

Sources: Mirage News, Phys.org, Cosmos Magazine