Material Innovations for Electric Aircraft: Progress in Battery Electrodes and Lightweight Fuselage Structure

Abstract

 The rapid growth of the low-altitude economy has spurred the development of electric aircraft as a sustainable transportation solution. However, the heavy weight of traditional fuselage materials and limitations in battery energy density and safety pose significant challenges to enhancing aircraft performance. The purpose of this review is to examine how lightweight fuselage materials (such as carbon fiber composites and aluminum alloys) and advanced battery materials (including lithium-ion batteries and solid-state batteries) can be utilized in electric aircraft. Key findings indicate that while advanced lightweight materials, particularly carbon fiber composites, offer substantial gains in structural efficiency, significant challenges related to cost and manufacturing/recycling persist; Alternative materials present trade-offs in performance or environmental resistance. For power systems, lithium-ion batteries are prevalent but suffer from safety risks, while solid-state batteries show promise yet require breakthroughs in material stability and interfacial issues. The review identifies the most promising material combinations, underscores the decisive impact of material properties on aircraft range, payload, and safety, and outlines future research directions to overcome current barriers. This review provides insights into optimizing material selection and promoting the commercial viability of electric aircraft, thereby supporting the expansion of the low-altitude economy.