As the eVTOL (electric Vertical Takeoff and Landing) aircraft industry moves from concept to reality, it brings with it a massive shift in how flight-ready components are designed, engineered, and manufactured. These next-generation aircraft—designed for urban air mobility, cargo transport, and autonomous missions—demand lightweight, high-performance, and ultra-precise components. And at the heart of that production? CNC machining.
From structural frames to sensor enclosures, CNC machined parts are essential building blocks in the rapidly growing eVTOL space. But what exactly are these parts? What makes them unique? And why is CNC machining the go-to method for producing them?
Let’s explore the most in-demand CNC machined parts requested by eVTOL aircraft developers—and how they contribute to the future of electric aviation.
🔩 1. Airframe and Structural Components
The skeleton of an eVTOL aircraft must be strong enough to support payloads and dynamic flight loads, yet light enough to maximize battery efficiency. CNC machining is used to create precision components for:
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Aluminum and titanium brackets
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Wing spars and rotor support arms
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Mounting plates for avionics and batteries
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Modular frame connectors
These parts are often machined from 7075 aluminum, Ti-6Al-4V titanium, or carbon fiber interfaces to ensure high strength-to-weight ratios. Tolerances must be tight to guarantee structural stability and minimize vibration during flight.
⚙️ 2. Propulsion System Parts
eVTOL aircraft depend on multiple electric motors and propellers for lift, thrust, and control. These systems require precisely machined parts for smooth and safe operation:
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Motor housings and rotor hubs
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Stator and bearing mounts
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Propeller blade clamps
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Gearbox and shaft components
Many of these components are multi-axis machined from heat-resistant metals like stainless steel or aircraft-grade aluminum, with smooth finishes to reduce wear and friction.
🎛️ 3. Flight Control and Actuator Components
Precise control is critical in eVTOL aircraft, which rely on electronic flight control systems rather than manual pilot inputs. CNC machining is used to manufacture:
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Servo mounts and actuator housings
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Linkage arms and pivot points
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Control rod ends and miniature joints
These parts are often small but must be incredibly strong and durable, with tolerances often in the micron range. Swiss machining is commonly used for smaller actuator elements.
🧠 4. Avionics and Sensor Mounting Parts
eVTOL aircraft integrate a wide range of sensors for navigation, obstacle avoidance, flight stabilization, and communication. These systems require precision-machined components for reliable performance, including:
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Sensor brackets and camera mounts
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Radar and LiDAR enclosures
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GPS and antenna housings
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Cooling plates for avionics processors
These parts are usually made from lightweight aluminum or high-temperature polymers and must fit tightly within compact spaces in the fuselage or landing gear.
🔋 5. Battery and Energy System Components
Batteries are the heart of electric flight. eVTOL aircraft require secure, thermally managed compartments to house and protect energy systems. CNC-machined parts include:
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Battery housing frames and casings
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Cooling plates and heat sinks
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Electrical isolation covers
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Mounting rails for modular battery packs
These parts must be heat-resistant, vibration-proof, and safely isolated, often using materials like aluminum, copper, and high-performance plastics.
🧯 6. Thermal Management and Fluid System Parts
With compact propulsion and power systems packed into tight spaces, heat dissipation is a major design challenge. CNC machining plays a role in producing:
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Liquid cooling blocks and micro-channel plates
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Compact manifolds for coolant distribution
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Pump and valve housing units
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High-pressure fluid connectors and fittings
These parts demand tight tolerances, corrosion resistance, and complex internal channels—making CNC machining (especially 5-axis and EDM) the preferred method.
⚡ 7. Landing Gear and Suspension Components
Even lightweight eVTOL aircraft require strong, impact-resistant landing gear that can handle vertical landings and varying terrain. CNC-machined components include:
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Shock-absorbing struts and mounts
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Landing leg joints and pivots
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Attachment arms and skids
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Actuated retractable mechanisms
Durability is key here, with parts often made from titanium, stainless steel, or chromoly alloys and treated for extra fatigue resistance.
🧷 8. Custom Fasteners and Connectors
Standard bolts and nuts don’t always fit the needs of lightweight aerospace designs. eVTOL aircraft often require custom-machined fasteners, including:
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Threaded inserts for composite materials
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Miniature locking pins and clips
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Vibration-resistant washers and spacers
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Captive screws for tool-less assembly
These components may be tiny, but they’re essential for modular construction, ease of maintenance, and weight optimization.
🧪 CNC Machining Techniques Used in eVTOL Manufacturing
To produce the components listed above, the eVTOL industry relies on a wide range of CNC machining processes, such as:
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5-Axis CNC Milling – For complex geometries and part consolidation
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Swiss-Type Machining – For small, ultra-precise components
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CNC Turning – For shafts, bushings, and circular housings
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Wire EDM & Sinker EDM – For high-precision slots, holes, and internal contours
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CNC Drilling & Tapping – For threaded inserts and assembly points
Most parts are machined from aerospace-grade materials, including aluminum alloys, titanium, PEEK, Ultem, and carbon fiber composites with metal interfaces.
The eVTOL aircraft industry is shaping the future of urban air mobility—and CNC machining is one of the foundational technologies making it possible. From propulsion to electronics, every system in these aircraft depends on accurately machined, lightweight, and reliable parts that meet the highest standards of aerospace engineering.
As demand for eVTOL aircraft continues to soar, CNC machine shops that specialize in tight tolerances, advanced materials, and agile production will play a pivotal role in building the next generation of electric flight.