The next frontier: Autonomous freighters

Autonomous air freighters, as they are currently conceived, are aircraft piloted from the ground with integrated autonomous systems. These freighters resemble modern autopilot systems, but the major difference lies in the ground-based pilot monitoring the aircraft via camera.

As we look toward a future where autonomous technologies gain prominence, it's critical to recognize the role that Unmanned Aerial Vehicles (UAVs) can play in achieving net-zero emissions goals in the air cargo industry.

UAVs, designed with energy-efficient features and capable of running on sustainable fuels or electric power, present an opportunity to significantly reduce the carbon footprint of air freight operations. This makes the cargo sector not just a testing ground for autonomous technologies, but also a pioneer in sustainable aviation.

Here Cargo Facts Consulting explores the benefits, challenges, and key players embracing both autonomy and hydrogen fuel-cell technology. Players in the UAV freighter market Natilus is among the most promising manufacturers in this sector. With FAA approval for testing, it is furthest along in development. Its aircraft feature a blended-wing-body (BWB) design, which offers 60% more volume than competitors at comparable payload capabilities.

The company plans to introduce 4-, 60- and 100-tonne-capable autonomous freighter models that could disrupt the freighter market. However, only the 4-tonne regional Kona is in testing and it has yet to make its first full-scale flight.

CFC had the opportunity to speak with Natilus Chief Executive Aleksey Matyushev at the Cargo Facts Symposium last month in San Diego, Calif.

"Hydrogen-powered aircraft are around 10 years away," he said, suggesting a viable solution to the current ESG concerns and future environmental regulations.

Matyushev’s presentation showed the innovative placement of the liquid hydrogen tank in the BWB design. The tanks utilize the corners and front of the aircraft, where standard LD3 crates leave unused space. This is significant since hydrogen storage has been a concern for modern aircraft layouts. Maintenance and servicing access to these tanks also sets Natilus apart from designs including standard wing tanks or fuselage storage, which are harder to retrofit. Figure 1 - Concept Natilus’ BWB design

Recently, CFC sister publication Cargo Facts reported on Droneliner , a London-based company planning to offer two models, the DL350 and the DL200, with payload capacities of 385 and 220 tonnes, respectively. Droneliner aims to offer a hydrogen-powered solution to propulsion along with Natilus. Testing for the models is slated for 2035, and Droneliner’s large-capacity capabilities are focused on shipping containers in contrast to the traditional air cargo LD3 crates.

Although Droneliner is in the early stages, an autonomous aircraft capable of transporting large shipping containers has the potential for major market disruption. Figure 2 - Concept Droneliner DL350 loading cargo containers

Smaller operations, major players As for smaller cargo operations with major players, FedEx, Amazon, DHL, and UPS are actively exploring and testing drone delivery services to enhance efficiency.

FedEx has partnered with Elroy Air for autonomous cargo drone deliveries, while Amazon aims for 30-minute delivery turnarounds with its Prime Air Service drones. DHL is developing the Parcelcopter for small packages, and UPS has received FAA approval for a drone airline focusing on medical deliveries.

As these major companies invest in autonomy — initially through drones — investments are likely to expand into the larger freighter market when pioneers prove successful. Regulatory challenges The task of securing regulatory approval for autonomous aircraft weighing between 60 tonnes and 385 tonnes is enormous. However, Natilus has already gained FAA approval for test flights and seems to have a solid relationship with the U.S. regulator. Droneliner is still in the R&D phase and therefore has not obtained FAA or EASA approval. Though testing for autonomous operations is expected to be time-consuming, the regulatory environment seems primed to change more quickly than in the past. The urgency appears to be greater with economic uncertainties that are leading to skyrocketing operating costs, a much-discussed topic in the industry. A market shift is anticipated as current-generation aircraft begin to phase out between 2030 and 2040, and options for replacements appear to be limited. The speed of this shift will hinge on the successful testing of autonomous and hydrogen-full technologies in the 2030s as well as the new generation aircraft to be offered by manufacturers. Hydrogen benefits, challenges The benefits of H2 (hydrogen) propulsion are clear. The liquid energy density compared to jet fuel is superior, there are zero emissions when using it for propulsion and it can be used in fuel-cell technology.

Fuel cells require fewer moving parts for engine operation, leading to reduced maintenance costs and longer operational lifespans. These benefits are noteworthy in a volatile oil market. However, there are steep up-front costs for hydrogen technology, and infrastructure for storage and distribution is largely inadequate.

Hydrogen, without cooling assistance, exists only as a gas on Earth’s surface, which presents a problem. This gaseous state is less dense and takes up more volume than liquid H2 and conventional jet fuel, a significant drawback given the premium on aircraft storage space. To solve this, H2 can be converted into liquid form but storage temperatures are a challenge.

Liquid hydrogen is most likely the future for H2 propulsion for aircraft but there are only a few companies that offer those services.

Hydrogen was a topic in discussions on sustainability and ESG goals during the Cargo Facts Symposium. David Waddington , director of sustainability marketing at Airbus, spoke about an H2-powered aircraft prototype by 2035 and a fleet transition by 2050. Airbus is still unsure whether hydrogen-electric fuel cell propulsion or hydrogen combustion in existing engines is the best course of action.

Representatives from Boeing briefly described hydrogen as a possibility for propulsion but did not seem to be pursuing the technology as actively as Airbus. Charting the Course: A New Era in Air Cargo As the landscape of air cargo undergoes a seismic shift, companies like Natilus and Droneliner are pushing the boundaries of what's possible with autonomous and hydrogen-powered technologies. Alongside them, logistical titans like FedEx, Amazon, DHL, and UPS are pursuing drone-based solutions, signaling an industry trend toward automation and sustainability.

Yet, for all the potential and promise, obstacles are numerous and substantial — regulatory complexities, the technological hurdles of hydrogen fuel storage, and the undetermined efficacy of these innovations in large-scale operations. However, these challenges also represent opportunities for transformative change that could redefine the industry.

Looking toward the future, the successes or setbacks of these pioneering initiatives will serve as a barometer for the industry’s readiness to embrace a new era of air cargo transport. This future holds enormous potential but also demands rigorous scrutiny and ongoing evaluation. We remain committed to tracking these developments closely, providing you with informed insights into these game-changing technologies.

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