A plane that can hover while being powered by a combination of fuel and batteries is the lofty creation of Lindsay, Ont.-based New Horizon Aircraft Ltd. (HOVR-Q).

Called the Cavorite X7, the firm hopes it will be a faster and more sustainable alternative to helicopters.

Horizon's hybrid-electric vertical take-off and landing (VTOL) plane can hover thanks to 14 fans embedded in the wings. The turbine engine that powers the thrust uses traditional jet fuel, while the VTOL capabilities tap into the battery that can be charged by a plug or electricity produced by the engine’s generator.

“It essentially means an aircraft that can take off and land like a helicopter, but is much cheaper to own and operate and about twice as fast. So the economics compound: (a) cheaper, faster helicopter that’s much more environmentally sustainable,” Brandon Robinson, the co-founder and CEO of Horizon, told Sustainable Biz Canada in an interview.

A former fighter jet pilot in the Canadian military with an educational background in mechanical engineering and business management, he sees the Cavorite X7 as a solution for remote communities in need of medical and emergency help while also cutting carbon emissions compared to helicopters. 

Horizon taking off

After years in “a pretty aggressive role” while also trying to help people in trouble, Robinson said his goal is to build machines that are “a better way of doing business” while being more sustainable and “leave our future in a much better place for our next generations.”

In 2017, a private investor asked the company to design a VTOL aircraft that uses electric propulsion. At the time, “everyone was very, very excited about all-electric aviation and especially all-electric VTOL,” Robinson said. But after considering the engineering, Horizon’s team realized such an aircraft would be challenging to operate efficiently in most situations.

A key problem is that today's batteries do not have enough energy capacity to compete with fuel, he explained. If a purely electric plane were to be made today, it would need an enormous amount of batteries, adding weight to the aircraft and limiting its potential applications.

Instead, a hybrid-electric plane that uses fuel and batteries was designed as a more feasible option. The team drew up a concept and built a prototype, with a research grant from the United States Air Force to help out. It has “performed above our expectations,” for power, stability and control, Robinson said.

Being built near Toronto, where Horizon has a hangar and manufacturing site, the prototype Cavorite X7 has taken flight.

Estimates suggest a full-sized X7 could have a maximum range of 800 kilometres and a top cruising speed of 450 km/h. It is being designed to carry up to six passengers, with a useful payload of 680 kilograms.

“Our hybrid-electric concept has an order of magnitudes less batteries on board and carries an order of magnitudes more stuff,” he said.

Sustainable alternative to helicopters

The hybrid technology means the Cavorite X7 will emit up to 30 per cent less greenhouse gas emissions compared to similar aircraft, Horizon claims.

Its potential uses are tasks helicopters typically perform, such as medical evacuations, organ and medication transportation, and disaster relief in rural areas. Other uses are handling the logistics for fighting wildfires or moving goods to the remote areas of Canada’s North in the winter, Robinson explained.

Though aviation is responsible for a relatively small two per cent of global greenhouse gas emissions, the International Energy Agency notes it is a rising figure and a difficult industry to decarbonize. Improving the efficiency of aircraft and engines is a key area to address, as well as producing low-emission fuels and optimizing operations.

Where Horizon wants to land

After attracting significant interest (so much the company had to give out many "no" responses), Robinson said Horizon is starting to sign deals. JetSetGo, a private airline in India, has expressed interest in the rights to the first 50 Cavorite X7s, with another optional 50 units in a deal that ranges in value from $250 million to $500 million, he said.

Robinson is confident a full-scale model will soon be available for final testing, and Horizon plans to release a certified model by 2028.

Keeping the company in Canada is a priority, Robinson said. The company plans to manufacture its planes in southern Ontario, despite some calls to move to the U.S.

A $6.7-million investment and a US$2.9-million funding round was raised by the company. More funding is expected to be raised in 2025, Robinson said. The company hopes to double its team from approximately 20 now to over 40 by 2025.

Eventually, Horizon may develop an entirely battery-powered aircraft. Robinson said he is waiting for more “battery breakthroughs” to make the change, but he is optimistic about the pace of improvements in capacity.