JetZero: Innovative Blended-Wing Aircraft Set for Takeoff

The basic design of commercial airplanes has remained relatively unchanged for the past 60 years. Despite advancements in technology, modern airliners such as the Boeing 787 and the Airbus A350 still bear a resemblance to older models like the Boeing 707 and the Douglas DC-8. These older models established the popular “tube and wing” design that continues to be used today.

This consistency in design can be attributed to the aviation industry's strong focus on safety. The industry prefers to stick with proven solutions rather than risking new and untested designs. Additionally, advancements in materials and engines have allowed the traditional airplane design to remain relevant and efficient.

A seismic shake-up is on the horizon as California skies are set to welcome a brand-new aircraft shape. Long Beach-based JetZero recently revealed that its Pathfinder, a 1:8 scale “blended wing body” demonstrator plane, has received an FAA Airworthiness certificate. Test flights are now on the horizon.

The aviation industry is currently under pressure to reduce carbon emissions, presenting a unique challenge due to the difficulty in moving away from existing core technologies. However, this challenge also presents a ripe opportunity for innovation.

The "blended wing body" is a design similar to the "flying wing" used by military aircraft like the B-2 bomber, but with more volume in the middle section. Both Boeing and Airbus are exploring this concept, and JetZero's recent progress brings them closer to their goal of introducing a blended wing aircraft by 2030.

JetZero's co-founder and CEO, Tom O'Leary, expressed strong belief in achieving zero emissions in large jets through the blended wing airframe. He stated in an interview with CNN in August 2023 that this design could lead to a 50% reduction in fuel burn and emissions, a significant advancement for the industry.

A rendering of JetZero's blended wing design.

A rendering of JetZero's blended wing design.

JetZero

Under pressure

The concept of the blended wing is not a new idea, with early attempts dating back to the late 1920s in Germany. American aircraft designer Jack Northrop developed a jet-powered flying wing design in 1947, which later influenced the B-2 bomber in the 1990s.

The blended wing design combines features of a flying wing and a traditional "tube and wing" aircraft, allowing the entire plane to generate lift and reduce drag. According to NASA, this shape improves fuel efficiency and creates larger payload areas in the center body of the aircraft. NASA has tested this concept using its experimental plane, the X-48.

Over the course of approximately 120 test flights conducted from 2007 to 2012, two unmanned X-48 aircrafts showed that the concept was feasible. According to the agency, this type of aircraft would have a wingspan slightly larger than a Boeing 747 and could function from current airport terminals. Additionally, it would be lighter, produce less noise and emissions, and be more cost-effective to operate compared to a similarly advanced traditional transport plane.

NASA's experimental X-48 plane.

NASA's experimental X-48 plane.

NASA

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In 2020, Airbus created a small-blended wing demonstrator, which was around six feet long, showing their interest in developing a full-size aircraft in the future. But despite the effectiveness of this design, why haven't we seen planes built based on it yet?

According to O'Leary, the main technical challenge that is holding manufacturers back is the pressurization of a non-cylindrical fuselage. He explains that a tube-shaped plane is better equipped to handle the constant expansion and contraction cycles that occur during each flight.

A 'tube and wing' design separates the pressurization load on the tube and the bending loads on the wings. However, a blended wing combines these loads together, made possible by lightweight and strong composite materials.

This innovative shape would create a significantly different interior compared to current widebody aircraft. The fuselage would be much wider, resembling a shorter and wider tube. Instead of the typical three by three seat configuration of single-aisle planes, there could be 15 or 20 rows across the cabin, depending on how each airline chooses to set it up.

"It will be exciting to see how they use this larger space to create something new and innovative."

JetZero hopes to have its plane in service by 2030.

JetZero hopes to have its plane in service by 2030.

JetZero

O’Leary mentions that a comparable aircraft in terms of size would be the Boeing 767, a widebody, twin-engine plane that first came into service in the 1980s and could usually accommodate about 210 passengers. While it is still being manufactured as a cargo plane, it has been succeeded by the Boeing 787 as a passenger aircraft. Additionally, there is a contemporary military version known as the KC-46, utilized by the US Air Force for aerial refueling.

JetZero is planning to develop three variants at the same time: a passenger plane for over 200 passengers, a cargo plane, and a fuel tanker. The blended wing design is particularly suitable for the fuel tanker, leading to a $235 million contract from the US Air Force to create a full-scale demonstrator. This will help validate the effectiveness of the blended wing concept, with the military version of the plane taking the lead and potentially supporting the development of commercial models.

The newly approved Pathfinder by the FAA has a 23-foot wingspan and is a 12.5%-scale model of the full-scale demonstrator. It is expected to take its first flight by 2027. The plane is specifically designed to be fully compatible with Sustainable Aviation Fuel (SAF) and has enough internal space to accommodate zero-carbon emissions hydrogen.

Building a new airplane from scratch is a big challenge, and JetZero's goals may seem ambitious since the certification process for a new aircraft can take years. One advantage JetZero has is that initially, the plane will use engines from current narrowbody aircraft like the Boeing 737. However, the ultimate plan is to transition to hydrogen-powered engines for zero emissions, which are still in development.

While JetZero has not yet received any orders for its plane, O'Leary mentioned to CNN that there is interest from airlines. He shared, "We are already in discussions with major airlines worldwide because they are excited about the potential efficiency improvements."

It is uncertain if a 50% decrease in fuel consumption can be achieved. NASA and Airbus aimed for a more conservative 20% reduction in their designs. On the other hand, the US Air Force believes that a blended wing aircraft could enhance aerodynamic efficiency by at least 30% compared to current Air Force tanker and mobility aircraft.

What the full-size JetZero plane could look like.

What the full-size JetZero plane could look like.

JetZero

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Bailey Miles, an aviation analyst at AviationValues consulting firm, emphasizes that although a blended wing body can help reduce drag and improve fuel efficiency, the actual advantages will vary based on the design, setup, and operating circumstances.

"Extensive aerodynamic testing and optimization are crucial to maximize the drag reduction capabilities of this new aircraft design. Without conducting the required tests, it is difficult to determine the exact amount of fuel savings," he explains.

According to Miles, the blended wing concept is considered a groundbreaking idea with great potential. However, it presents several challenges such as increased aerodynamic complexity during design and testing, regulatory obstacles for certification, and a unique shape that may not be compatible with current airport facilities.

The blended wing body aircraft is seen as a game changer in the aviation industry due to its potential for improved fuel efficiency, enhanced payload capacity, and innovative control systems. However, there are significant challenges that need to be addressed before it can become a reality, such as aerodynamic complexities, structural integrity, regulatory hurdles, and airport infrastructure.

Richard Aboulafia, an aviation analyst at consulting firm Aerodynamic Advisory, acknowledges that not all of JetZero's claims can be verified. He mentions that the concept of a blended wing body has been appealing for years and it seems like JetZero has conducted interesting research. Aboulafia and his colleagues see the idea as quite promising, despite the challenges that may make JetZero's target of 2030 for entry into service seem "inconceivable."

He is worried that the company is currently mainly focused on design, but he thinks that the project could succeed with the assistance of contractors. He mentions, "There is definitely space for someone who is eager to make a difference in this field."

Editor's P/S:

The aviation industry has long been in need of a shake-up, and the blended wing body aircraft has the potential to be just that. This new design promises to reduce fuel consumption and emissions by up to 50%, which would be a major step forward in the fight against climate change. Additionally, the blended wing body design could allow for more efficient use of space, which could lead to more comfortable and spacious cabins for passengers.

However, there are also significant challenges that need to be addressed before the blended wing body aircraft can become a reality. These challenges include aerodynamic complexities, structural integrity, regulatory hurdles, and airport infrastructure. It will be important for JetZero and other companies working on this design to work closely with regulators and airport authorities to ensure that these challenges can be overcome. If they can be successful, the blended wing body aircraft could revolutionize the way we fly.