Propeller blade separation leads to eVTOL crash during flight test

Casualties unknown • Cotswold Airport (Kemble), Gloucestershire, GB

An experimental electric vertical takeoff and landing aircraft sustained significant structural damage after a propeller blade detached during a remote-controlled test flight at Cotswold Airport.

What happened

On 9 August 2023, the VA-1X, registration G-EVTL, was conducting an experimental flight test at Cotswold Airport (Kemble). The aircraft, an electric vertical takeoff and landing (eVTOL) prototype, was being operated remotely under the CAA Specific Category1. The mission involved testing one-engine-inoperative performance during a hover out of ground effect.

During the flight, the aircraft reached an altitude of 30 ft agend. As the aircraft began to accelerate at a ground speed of approximately 2-4 kt, a propeller blade detached from the third electric propulsion unit (EPU3). The sudden loss of the blade created massive out-of-balance forces, which caused the structural failure of the right inboard pylon. This failure subsequently severed critical wiring harnesses, leading to a loss of thrust from motors 4 and 7. Although the flight control system managed to keep the aircraft level, the reduction in vertical thrust caused a rapid descent. The aircraft struck the edge of the runway at a vertical descent rate of 19.45 ft/sec, resulting in no injuries but causing extensive damage to the right wing, fuselage, landing gear, and engine pylon.

Probable cause

The primary cause of the accident was the separation of a propeller blade sheath from its spar due to a failure in the adhesive bond. This separation created severe imbalances that destroyed the aircraft's pylon and damaged the electrical systems, preventing the aircraft from maintaining sufficient thrust to avoid a high-velocity impact with the ground.

Frequently asked questions

What happened in the 2023-10-09 VA-1X accident near Cotswold Airport (Kemble), Gloucestershire, GB?

An experimental electric vertical takeoff and landing aircraft sustained significant structural damage after a propeller blade detached during a remote-controlled test flight at Cotswold Airport.

What aircraft was involved and where did it happen?

The accident on 2023-10-09 involved a VA-1X, registration G-EVTL, at Cotswold Airport (Kemble), Gloucestershire, GB.

What was the probable cause of the accident?

The primary cause of the accident was the separation of a propeller blade sheath from its spar due to a failure in the adhesive bond. This separation created severe imbalances that destroyed the aircraft's pylon and damaged the electrical systems, preventing the aircraft from maintaining sufficient thrust to avoid a…

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