Horizon Aircraft Selects RAMPF to Manufacture the Cavorite X7 Composite Fuselage
Building the Future of Regional Air Mobility with Advanced Composite Manufacturing
Horizon Aircraft has selected RAMPF to manufacture the fuselage of its hybrid-electric eVTOL Cavorite X7.
Designed around the real-world needs of operators and passengers, the Cavorite X7 combines the flexibility of vertical takeoff and landing with the efficiency, speed, and range of conventional flight.
The project demands a lightweight, structurally robust fuselage designed to deliver exceptional aerospace performance. Leveraging its extensive expertise in aerospace composite engineering and manufacturing, RAMPF is producing the fuselage using advanced composite materials that combine high strength, durability, and weight savings, helping enhance efficiency and long-term durability.
The collaboration brings together Ontario-based manufacturing expertise in Canada with aerospace-grade quality standards to advance the development of next-generation sustainable aviation solutions.
Customer Profile
Horizon Aircraft
Industry: Aerospace / Advanced Air Mobility (AAM)
Application: Hybrid-Electric eVTOL Aircraft
Project: Cavorite X7
The Cavorite X7 combines the vertical takeoff and landing capabilities of a helicopter with the speed, range, and efficiency of a conventional airplane. Using patented fan-in-wing technology, it can operate from confined spaces while delivering high-speed regional transport for passengers, cargo, medevac, defense, and emergency-response missions.
Challenge
Engineering a High-Performance Composite Fuselage for Next-Generation Aviation
- Infusing a large aircraft fuselage is one of the most demanding composite manufacturing processes.
- Large structures require a resin system with sufficient working time.
- Resin must reach every fiber across the entire part before gelation begins.
- Precise control of the resin flow front is essential.
- Otherwise, dry spots and edge race-tracking can occur, compromising part quality.
- At the same time, tooling must maintain dimensional stability under full vacuum to ensure geometric accuracy throughout the infusion process.
Solution
Advanced Aerospace Composite Manufacturing from RAMPF
- Used flow modelling upfront to predict and optimize resin flow throughout the entire structure.
- Planned the infusion strategy before production began, reducing manufacturing risk and improving process predictability.
- Selected a resin system with sufficient working time to achieve complete wet-out of the large, complex structure.
- Designed and manufactured dimensionally stable tooling capable of maintaining its shape under full vacuum.
- Combined optimized flow modelling, process planning, tooling, and material selection to ensure consistent part quality.
- Successfully produced a large, complex aerospace structure on schedule and to specification.
Horizon Aircraft selected RAMPF for its proven expertise in engineering and manufacturing aerospace composites, including large, complex composite fuselages. Combining advanced composite manufacturing capabilities with experience in mission-critical aircraft and defense structures, RAMPF supports eVTOL and advanced air mobility programs with reliable production, reduced development risk, and consistent quality.
Customer Perspective
From a manufacturing perspective, the X7 pushes the boundaries of what's possible in advanced aviation. Far more than a futuristic concept, it combines validated flight data, hybrid-electric propulsion, and a highly efficient wing design, making it one of the most credible next-generation aircraft in development today. With this program, we are pioneering a transformative new approach to sustainable air mobility.
Brandon Robinson, CEO & Co-Founder, Horizon Aircraft
RAMPF Perspective
By combining advanced production technologies with premium composite materials, RAMPF consistently meets the most demanding industry standards. A key contribution to this partnership is our fully integrated production approach – an end to end capability that accelerates time to market, reduces costs, and ensures exceptional quality throughout the entire build process.
Larry Fitzgerald, CEO, RAMPF Composite Solutions
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FAQ
The Cavorite X7 combines vertical takeoff and landing capabilities with the range and operational efficiency of a conventional aircraft, targeting regional air mobility applications.
Advanced composite materials provide an exceptional strength-to-weight ratio, enabling improved aircraft efficiency, durability, and performance.
Key benefits include:
- Weight reduction
- High structural strength
- Corrosion resistance
- Long service life
- Greater design flexibility
RAMPF Composite Solutions is responsible for manufacturing the composite fuselage, a critical structural component of the Cavorite X7 aircraft.
Local production supports close collaboration between development and manufacturing teams, improving communication, quality control, and project execution.