VX4 by THE ROCKWOOD GROUP

Rockwood Aerospace has developed a novel manufacturing process for propeller blades tailored to electric vertical take-off and landing (eVTOL) aircraft. For Vertical Aerospace’s VX4 Prototype Aircraft it developed a proprietary single-shot compression moulding technique that integrates carbon fibre pre-preg, foam cores, and metallic hardware in one cure cycle. This eliminates secondary bonding, yielding blades that are lighter, stronger, and more fatigue-resistant than those from resin infusion or bonded skin-and-spar methods. 

The process is supported by Rockwood’s custom tooling and hot platen presses, enabling complex geometries and precise fibre placement. Few UK firms combine this expertise with scalability, giving Rockwood a clear advantage in the fast-growing eVTOL sector. 

For operators, the benefits are direct: reduced aircraft weight, meaning longer battery endurance, and enhanced safety. With global eVTOL markets projected to increase ~20-fold within a decade, Rockwood’s technology positions it for contracts with leading OEMs while also supporting their current aerospace and defence markets.