Configuration Trade-Off and Co-Design Optimization of Hybrid-Electric VTOL Propulsion Systems

Unmanned vertical takeoff and landing (VTOL) aircraft are increasingly deployed for logistics, surveillance, and urban air mobility (UAM) applications. However, the limitations of full-electric (FE) and internal combustion engine (ICE) systems in meeting diverse mission requirements have motivated the development of hybrid-electric (HE) propulsion systems. The design of HE powertrains remains challenging due to configuration flexibility and the lack of unified criteria for performance trade-offs among FE, ICE-powered, and HE configurations. This study proposes an integrated propulsion co-design framework coupling power allocation, energy management, and component capacity constraints through parametric system modeling. These interdependencies are represented by three key matching parameters: the power ratio (Φ), energy ratio (Ω), and maximum continuous discharge rate (rc). Through Pareto-optimal design space exploration, trade-off analysis results and optimization principles are derived for diverse mission scenarios such as UAM, remote sensing, and military surveillance. Different technological conditions are considered to guide component-level technological advancements. The method was applied to the power system retrofit of the Great White eVTOL. Subsystem steady-state tests provided accurate design inputs, and a simulation model was developed to reproduce the full flight mission. By comparing the simulation with flight-test measurements, mean absolute percentage errors of 8.91% for instantaneous fuel consumption and 0.26% for battery voltage were obtained. Based on these error magnitudes, a dynamic design margin was defined and then incorporated into a subsequent re-optimization, which achieved the 1.5 h endurance target with a 10.49% increase in cost per ton-kilometer relative to the initial design. These results demonstrate that the proposed co-design methodology offers a scalable, data-driven foundation for early-stage hybrid-electric VTOL powertrain design, enabling iterative performance correction and supporting system optimization in subsequent design stages.