Joby Aviation Ignites a New Era of Propeller Manufacturing in Dayton

In a move that bridges a storied past with a high-tech future, Joby Aviation has officially commenced manufacturing propeller blades for its electric vertical take-off and landing (eVTOL) aircraft in Dayton, Ohio. This announcement marks a critical milestone for the company as it progresses from research and development to scaled production, a necessary step on the path toward commercializing its electric air taxi service. The first blades are being produced at a facility near the Dayton International Airport, setting the stage for a significant ramp-up in the company’s manufacturing capabilities.

The choice of Dayton is anything but coincidental. Known as the “Birthplace of Aviation,” the city’s legacy is deeply intertwined with the history of flight, extending far beyond the pioneering work of the Wright Brothers. Specifically, Dayton was a powerhouse of propeller design and Manufacturing, particularly during the Second World War. By establishing its production in this historic hub, Joby is not just building a factory; it is deliberately tapping into a deep well of aerospace expertise and reviving a local manufacturing legacy that once equipped the aircraft that defined a generation.

This development represents the first operational phase of a much larger vision. Joby has committed to a significant investment in the region, with plans for a 140-acre campus that will eventually house its first scaled aircraft production facility. The start of propeller manufacturing is a tangible first step, signaling the company’s confidence in Dayton’s workforce and supply chain while laying the groundwork for a new chapter in advanced air mobility, both for Joby and for the state of Ohio.

A Strategic Return to Aviation’s Heartland

Joby’s decision to anchor its manufacturing in Dayton is a calculated move rooted in both history and modern logistics. The region’s identity is inseparable from aviation innovation. This legacy provides a unique foundation of talent and institutional knowledge that is difficult to replicate elsewhere. For decades, Dayton was a global leader in propeller technology, a history that Joby and state officials have consistently highlighted as a key factor in the decision-making process.

Reviving a Rich Propeller Legacy

Dayton’s reputation in propeller manufacturing was cemented long ago. In 1938, the city became home to McCauley Propeller Systems, a company that grew into the world’s largest propeller manufacturer for general aviation. McCauley was an innovator, developing the first ground-adjustable solid-steel propeller in 1941 and later, in 1947, the first all-metal propeller for light aircraft. This spirit of innovation is what Joby aims to channel as it develops the next generation of aviation technology.

The city’s role became even more critical during the 1940s. As a central hub for the war effort, Dayton’s industrial base churned out an incredible volume of aerospace components. Companies like the Aeroproducts division of General Motors and the Frigidaire Division of GM became major propeller manufacturers. Notably, Frigidaire produced all the propellers for the legendary B-29 bomber, while Wright Field alone was responsible for producing nearly 807,424 propellers during the war. Joby’s new facility is, in many ways, picking up a thread from this powerful manufacturing history.

This historical context provides more than just a compelling narrative; it translates into a tangible advantage. The generations of aerospace manufacturing have cultivated a highly skilled workforce and a network of suppliers specializing in the precise engineering required for aviation. Joby’s leadership has noted that many necessary components for its operations are available within a 30-minute radius of its new facility, a testament to the robust and mature local Supply-Chain.

“Dayton gives us the resources, talent, and speed to scale one of the most technically demanding parts of our aircraft.” – Eric Allison, Chief Product Officer at Joby

The Modern Advantages of a Historic Hub

Beyond its legacy, Dayton presents a compelling case for modern manufacturing. The project is backed by a strong public-private Partnerships, including up to $325 million in state and local incentives designed to attract and support this new wave of aerospace innovation. This support underscores a shared vision for the future of flight in the region. J.P. Nauseef, President and CEO of JobsOhio, noted that the investment reinforces “Ohio’s role in shaping the future of flight.”

Joby is beginning its Dayton operations by retrofitting an existing, underutilized facility at the Dayton International Airports. This pragmatic approach allows the company to begin production quickly while planning for a larger, purpose-built factory on its adjacent 140-acre site. Didier Papadopoulos, President of Aircraft OEM at Joby, highlighted this strategy, stating, “We’re pleased to be able to acquire an underutilized facility…and repurpose it as a modern, high-tech manufacturing center to serve as our initial manufacturing footprint in the region.”

The initial activities in this facility will not be limited to propellers. The site will also produce titanium and aluminum aircraft parts that will support the pilot production line in Marina, California. This phased approach allows Joby to integrate Dayton’s capabilities into its broader manufacturing network immediately, ensuring a smooth and efficient ramp-up as it moves toward full-scale production.

Engineering the Future: From Blades to Full-Scale Aircraft

The components being manufactured in Dayton are far from simple. Joby’s propeller blades are the result of more than a decade of intensive research and development. They are a cornerstone of the aircraft’s design, engineered to be exceptionally efficient and, crucially, to produce a very low acoustic signature. This quiet performance is a key enabler for the company’s vision of integrating air taxis into and around urban environments without creating significant noise disruption.

Advanced Manufacturing for a Revolutionary Design

The propeller blades are complex structures made from advanced carbon fiber composites. Their unique shape and construction are what allow the Joby aircraft to be remarkably quiet during takeoff, landing, and overhead flight. According to Chief Product Officer Eric Allison, these blades are “central to its low acoustic profile and the result of a decade of complex engineering.” Achieving the required precision and strength at scale is a significant manufacturing challenge.

To meet this challenge, Joby is leveraging its strategic partnership with Toyota. The automotive giant, renowned for its world-class manufacturing processes, has invested in Joby and is providing invaluable expertise to help streamline production. This collaboration is instrumental in developing the processes needed to manufacture these highly complex components consistently and efficiently, a critical step for achieving the scale required for commercial service.

The first “conforming” blades, which are those that meet all the stringent requirements for FAA (Federal Aviation Administration) certification, are expected to be completed in November 2025. These blades are slated for installation on flight test aircraft in 2026, marking a clear and tangible step forward in the aircraft’s certification journey. This timeline demonstrates a methodical progression from prototype to certified production hardware.

Scaling Up for Commercial Operations

The Dayton facility is designed with scale in mind. The initial production target is to manufacture up to 15,000 propeller blades annually. Each Joby aircraft is equipped with six propellers, and each propeller has five blades, for a total of 30 blades per aircraft. This production capacity will be sufficient to support the manufacturing of up to 500 aircraft per year, a volume that signals Joby’s serious intent to build and deploy a large-scale fleet.

This manufacturing launch is the first part of a much larger investment plan for Ohio. Joby has announced plans to invest up to $500 million in its Dayton campus, a project that is projected to create up to 2,000 jobs. The economic ripple effect could be substantial, with one estimate suggesting a potential statewide impact of $13 billion by 2045. This positions Joby not just as an aviation company, but as a future economic engine for the region.

The company plans to commemorate the start of production with an official event on November 10, 2025, celebrating the opening of the site and this new chapter in Dayton’s aviation story. As production ramps up, the Dayton facility will become a cornerstone of Joby’s mission to deliver fast, quiet, and clean aerial transportation to cities around the world.

Conclusion: Dayton’s Next Chapter in Aviation

Joby Aviation’s decision to begin propeller manufacturing in Dayton is a powerful synthesis of past and future. It is a nod to a rich historical legacy of aerospace innovation while simultaneously laying the foundation for the next generation of flight. By leveraging Dayton’s skilled workforce, established supply chain, and deep-rooted expertise, Joby is positioning itself to overcome the immense challenge of scaling production for a revolutionary new type of aircraft.

This move is more than just a corporate expansion; it represents a pivotal moment for the emerging advanced air mobility industry. It signals a shift from conceptual designs and prototypes to the tangible reality of a production line. As the first blades come out of the Dayton facility, they will represent not only a critical component for an aircraft but also a symbol of a renewed manufacturing legacy and a bold step toward a new era of aviation, firmly rooted in the city where it all began.

FAQ

Question: What is Joby Aviation manufacturing in Dayton?
Answer: Joby is manufacturing advanced carbon fiber propeller blades for its electric vertical take-off and landing (eVTOL) aircraft. These blades are a critical component, designed for quiet performance and efficiency.

Question: Why did Joby choose Dayton, Ohio?
Answer: Joby selected Dayton for its deep aviation history, particularly in propeller manufacturing, as well as its skilled aerospace workforce, robust local supply chain, and the significant support offered by state and local partners.

Question: How many jobs will this project create?
Answer: Joby’s total planned investment in its 140-acre Dayton campus is expected to create up to 2,000 jobs, making it a significant economic development project for the region.

Question: What are the production goals for the new facility?
Answer: The facility is projected to produce up to 15,000 propeller blades annually, which is enough to support the manufacturing of 500 aircraft per year.

Sources: Joby Aviation