Spanish startup Crisalion Mobility is carving out a unique position in the rapidly evolving landscape of advanced air mobility with its innovative approach to eVTOL aircraft development. Founded in 2020, the company is not just reimagining flight, it is also taking a holistic view of society’s future transportation
needs, combining the latest aerospace technology with ground-based remote operation technologies.
At the heart of Crisalion’s eVTOL design is its patented FlyFree system, a novel solution for one of the most challenging aspects of VTOL aircraft – transition from hover to forward flight. Oscar Lara, chief operating officer of Crisalion, says: “We can think about the system as an aircraft hanging from four drones. Each drone is connected to the aircraft through an arm, and the connection between the drone and the arm is a passive joint.”
This passive joint is a crucial element of the design, distinguishing it from the complex active tilting mechanisms used in many competing eVTOL designs.
Lara emphasizes the advantages of this approach: “An active mechanism can have reliability issues, can be expensive and may also present certification challenges. This passive system has none of those disadvantages.”
The FlyFree system works by varying the thrust of each rotor, allowing the entire set of four drones to tilt around the passive joints. This method enables the aircraft to transition smoothly from vertical to horizontal flight without the need for separate lift and cruise systems or complex mechanical tilting mechanisms. The benefits of this design extend beyond simplicity and associate potential cost savings associated with that: “The design uncouples the movement of the power plant from the cabin,” Lara says.
“This means more passenger comfort, and it allows us to fly in more adverse weather conditions.”
From concept to reality
Crisalion’s development journey began with scale models, progressing to a full-scale single-passenger technology demonstrator. This initial prototype, capable of 15-minute flights over 15km (9 miles), has served as a proof of concept for the FlyFree system. The company is taking a significant step forward with the core technology validated. Engineers have begun to design the commercial vehicle, a larger aircraft that will accommodate a pilot and five passengers. The latest design devised maintains the FlyFree system but adapts it for practical, real-world applications.
“We are currently manufacturing the first prototype of this new design,” Lara reveals. “We expect to begin flight testing within the coming months.”
The company’s ambitious timeline includes plans for a second prototype in 2026, followed by a conforming aircraft for full certification with the European Union Aviation Safety Agency (EASA) in 2028. Crisalion is targeting entry into service for this commercial model in 2030.
Notably, the production design is not limited to passenger transport. Lara emphasizes its versatility: “This is a multi-purpose aircraft. It is not just for passengers but also for cargo and emergency medical missions. We decided to account for all these requirements from the beginning of the design process.”
Integrating with air traffic systems
As eVTOL aircraft move closer to commercial reality, one of the most pressing challenges is how to integrate them with existing air traffic management (ATM) systems. Crisalion is taking a proactive approach to the issue by engaging actively with ATM stakeholders and participating in key demonstration programmes.
“We are very involved in discussions at the European level and in touch with regulators around the world,” Lara says. The company has participated in SESAR (Single European Sky ATM Research) demonstration programmes in France and the Netherlands, testing its prototype aircraft alongside detect-and-avoid systems and other enabling technologies.
These experiences have been valuable, allowing Crisalion’s engineers to validate the performance of the aircraft and the full operational concept. Lara underscores the importance of this collaborative approach: “We need to go together in the industry, develop the aircraft in parallel with ATM and other systems. We also need to work with many suppliers at the same time and we need to help them to develop the kinds of solutions that we need.”
Pragmatic implementation
Crisalion is taking a measured, step-by-step approach to its implementation. Lara envisions a gradual introduction of eVTOL aircraft operations, likely beginning with cargo and emergency medical services before expanding to passenger transport.
“Initially, I think we are going to see just a few flights,” Lara says. “It is probable that these flights may be out of very congested cities, just to test the operational concept.”
The cautious approach aligns with the company’s commitment to safety and its understanding of the aerospace industry’s regulatory landscape. It also applies to Crisalion’s approach to automation.
Many eVTOL aircraft developers see autonomous flight as a way to reduce operational costs and enable widespread adoption. However, Crisalion takes a pragmatic view of autonomy. While the company’s long-term vision includes the possibility of unmanned operations, its initial focus is on developing a piloted aircraft.
“Only China has evolved the kind of framework that allows unmanned passenger aircraft,” Lara notes. “In Europe and the USA, they are betting on first deploying this kind of aircraft with a pilot on board.”
Lara also points out that pilot costs are just one factor in the overall economics of eVTOL aircraft operations. “There are many other areas in which we have to make sure we keep our costs low,” he says.
“Like vertiports, ground handling, insurance and air traffic management. So, the focus should not only be on trying to remove the pilot in the future, but it should be on the whole ecosystem trying to work together.”
A holistic approach to mobility
What sets Crisalion apart from competitors is its comprehensive approach to future mobility. In addition to the development of its eVTOL Integrity, the company is working on a system called Intellydrive for the remote operation of ground vehicles.
“On the ground side, we are developing a system that lets you drive vehicles remotely from a Remote Control Centre,” Lara says. This technology could enable a gradual transition to autonomous ground transport while offering immediate benefits in terms of vehicle and driver efficiency.
This dual focus on air and ground mobility solutions gives Crisalion a fresh perspective on the future of transportation. “We have both ground and air platforms in development and we are taking a holistic approach to the mobility problem. We aim to be able to provide our customers with full mobility solutions that can interface smoothly between air and ground.”
The road ahead
As Crisalion prepares for the first flight of its new prototype in the coming months, the company is scaling up rapidly. It has around 60 employees currently and plans to grow to 100 by the end of 2024. Crisalion is backed by two private investors and the Spanish Government, demonstrating strong confidence in its vision and technology.
The company’s recent rebranding – changing its name to Crisalion – reflects its transformative ambitions.
“The name Crisalion comes from a chrysalis. We are a butterfly that is starting to extend its wings to start flying. We want to transition transport into something different,” says Lara.
As the aviation sector continues to evolve, Crisalion’s innovative technology, holistic approach to mobility, and measured implementation strategy position it as a company to watch. By focusing not just on aircraft design but on the entire ecosystem of future mobility, Crisalion is working to ensure that the promise of advanced air mobility can be fully realized.
The journey from concept to commercial reality in the aerospace industry is never simple, but Crisalion’s methodical approach, commitment to collaboration, and innovative technology provide a solid foundation for success. As Lara and his team continue their work, they are not just developing an aircraft but helping to shape the future of urban transport.