US startup tests autonomous cargo drone with 500-lb payload, 450-mile range

US drone startup Elroy Air has completed the first autonomous, uncrewed flights authorized under the government’s eVTOL Integration Pilot Program (eIPP). The company conducted the flights using its Chaparral hybrid-electric vertical takeoff and landing aircraft in Louisiana. The week-long demonstrations were carried out with partners and focused on transporting different types of cargo, including medical supplies, food, and industrial equipment. “These test flights demonstrate how these new aircraft can expand cargo delivery options to communities nationwide and improve our logistics infrastructure,” said Bryan Bedford, Federal Aviation Administration (FAA) Administrator, in a statement. Chaparral flies autonomously Elroy Air completed a new series of autonomous, uncrewed flight tests of its Chaparral cargo aircraft under the US Department of Transportation and FAA’s eIPP project. The project aims to safely integrate Advanced Air Mobility aircraft into US airspace, using operational data to shape aviation policy and support wider commercialization. Conducted in Houma, Louisiana, the week-long tests marked the first autonomous and uncrewed flights authorized through the federal program, bringing the aircraft closer to commercial operations. Chaparral flew without a pilot onboard while operating under Air Traffic Control oversight, demonstrating its ability to conduct cargo missions within the National Airspace System. The tests included transporting packages, medical supplies, food, water, and industrial equipment, providing a practical demonstration of the aircraft’s autonomous cargo capabilities. Elroy Air conducted the flights with LIFTOFF Louisiana and Bristow Group, using the tests to evaluate Chaparral in an operational environment relevant to potential commercial deployment across the Gulf Coast. The hybrid-electric VTOL aircraft is designed to carry more than 500 pounds (227 kilograms) of cargo and travel up to 450 miles (724 kilometers). Elroy Air said the latest flights will help inform the company’s efforts to deploy autonomous heavy-cargo aircraft safely and at scale. The tests also generate operational data for the eIPP as regulators and industry partners work toward integrating advanced air mobility aircraft into US airspace. Chaparral features interchangeable cargo pods, enabling operators to adapt the aircraft for different missions without altering its core platform. Its VTOL capability also eliminates the need for runways, fixed delivery infrastructure, or personnel at the destination, expanding its potential use in disaster relief, maritime missions, and remote areas. Chaparral boosts logistics Recently, Elroy Air expanded the capabilities of its autonomous Chaparral cargo aircraft with three unattended delivery modes developed for the US Army. The new system allows the drone to release supplies while hovering, drop payloads during forward flight, or land and unload cargo autonomously, eliminating the need for personnel or dedicated equipment at the receiving site. The company demonstrated the capabilities during a July 15 flight test at its headquarters in Byron, California. During the test, Chaparral autonomously released a 68-pound (30 kilograms) payload while hovering over a designated target before dropping a second 70-pound (31 kilograms) payload from forward flight at an altitude of 65 feet. Both deliveries used preloaded coordinates and were completed without intervention during the release sequence, demonstrating the system’s ability to operate in communications-denied environments. A separate test demonstrated the aircraft’s autonomous ground delivery capability. After landing, Chaparral released its cargo before taking off again, allowing supplies to be delivered without ground crews or specialized unloading infrastructure. The US Army requested the capabilities under an existing development contract. The new delivery modes are intended to support resupply missions in contested, remote, or infrastructure-limited environments. The same technology could also be applied to commercial logistics operations where conventional delivery infrastructure is unavailable. Get the latest in engineering, tech, space & science - delivered daily to your inbox.Jijo is an automotive and business journalist based in India. Armed with a BA in History (Honors) from St. Stephen's College, Delhi University, and a PG diploma in Journalism from the Indian Institute of Mass Communication, Delhi, he has worked for news agencies, national newspapers, and automotive magazines. In his spare time, he likes to go off-roading, engage in political discourse, travel, and teach languages.