Rotron Aerospace

Rotron Aerospace’s journey began long before its first engine ever turned. At fifteen—in an era before the internet—founder and CTO Gilo Cardozo read a magazine article about a mysterious flying machine: a paramotor. The idea fascinated him, but one question lingered — how did it actually fly?

Driven by curiosity, Gilo set out to understand how a man could appear to fly with nothing more than a motor on his back. To a fifteen-year-old, the mechanics weren’t obvious; discovering the wing above the pilot was a revelation. That moment ignited a lifelong fascination with flight and the machines that make it possible.

Years later, Gilo was introduced to paramotoring by Colonel Charles Blount, an Army helicopter pilot and the father of singer and artist James Blunt. Early paramotors were heavy, loud and filled with vibration, limiting their potential. That experience sparked his determination to refine the heart of the system, the engine itself.

After years of experimentation, Gilo developed a compact rotary engine with only three moving parts, lighter, stronger and far smoother than the conventional two-strokes of the day. In 2007, he and close friend Bear Grylls, now godfather to Gilo’s children, put it to the ultimate test, flying a paramotor to the summit of Mount Everest. At nearly nine kilometres above sea level, in temperatures of –50°C and winds up to 320 km/h, the engine proved its performance in the harshest conditions on Earth.

That success laid the foundation for Rotron Aerospace’s mission to redefine propulsion. Today, the same rotary architecture powers advanced unmanned aerial vehicle (UAV) engines, delivering exceptional power-to-weight performance, low vibration and unmatched reliability for missions that demand more endurance, payload and precision.

UAV operators can choose between Rotron’s rotary engines, such as the RT600-XE, delivering around 100 horsepower or the more powerful RT1200-P, producing over 220 horsepower. Both engines remain within Group 3 limits, a category of unmanned aircraft defined as weighing less than 600 kg (1,320 lbs), flying below 18,000 feet and at speeds under 250 knots. For operators, this means UAVs that can stay airborne for more than ten hours, carry heavier payloads and deliver essentials such as ammunition, medical kits or spare parts on missions that were previously out of reach.

“With our technology, we’ve proven that rotary engines, once questioned for their reliability, can now deliver exactly what aerospace needs; compact power, smooth operation and reliability where other systems struggle,” says Cardozo.

FDS: Extending Reach with Speed and Stealth

The Fan Drive System (FDS) is Rotron’s next leap, taking the rotary architecture into a new domain of speed, range and survivability. Built on the same technology that powers its vertical take-off and landing (VTOL) platforms, the FDS is engineered for high-speed unmanned combat aerial vehicles (UCAV) and one-way effect systems, where covering distance and staying undetected are as critical as lift.

At its core is a ducted fan nacelle that fuses propulsion and flight control into a single unit. By eliminating external control surfaces, drag is reduced, aerodynamic efficiency improves and radar visibility drops, creating a streamlined platform optimised for contested airspace. The absence of conventional tails and wings further simplifies design while increasing agility at high speeds.

The performance targets redefine expectations for unmanned aviation. With a payload capacity ranging from 50 to 450 kg, the FDS reaches speeds approaching Mach 0.8, which is near the envelope of manned fighter aircraft. Its efficiency extends the range up to four times farther than a comparable turbojet while delivering that capability at a fraction of the lifecycle cost. For commanders, this means projecting effects deep into denied zones without risking manned assets.

By merging stealth, efficiency and reach into one architecture, the FDS unlocks missions that were previously out of reach. From long-range strike to rapid reconnaissance in hostile airspace, it equips operators with a system built for the evolving realities of modern warfare.

Proven Performance in Today’s Platforms

While the FDS points to the future, platforms like the DT-300 show how Rotron’s team and design philosophy are already redefining what UAVs can achieve. A heavy-lift VTOL aircraft built as a true multi-role system, the DT-300 reflects the company’s ability to combine smart engineering with precise manufacturing.

The proof of this expertise was seen in 2023, when it became the first UAV to launch an Advanced Precision Kill Weapon System (APKWS) laser-guided rocket and a Javelin anti-tank missile during live-fire demonstrations at a U.S. military proving ground. Just as decisively, it has proven its worth in frontline resupply and as a mothership for smaller drones operating deep inside contested areas.

At the same time, its Full Authority Digital Electronic Control (FADEC) acts as a digital brain, continuously managing power delivery, motor timing and load response in real time. Whether lifting off with a heavy payload or maintaining efficient cruise during extended ISR missions, the system optimises performance and endurance without compromise.

Advanced avionics and sensor fusion enhance reliability, maintaining stability even under GPS jamming conditions. Redundant systems, such as dual power buses and hardened electronics, provide fault tolerance. For operators, this means confidence that missions will continue even when conditions are at their worst.

Trusted by Aerospace Leaders Worldwide

Proven performance has earned Rotron Aerospace the confidence of aerospace leaders worldwide. Companies including Leonardo, IHI of Japan and Hindustan Aerospace have all integrated its propulsion into their platforms, recognising that Rotron’s rotary DNA delivers a standard of reliability and performance that few in the UAV space can match.

One of the clearest demonstrations of that trust came through a five-year collaboration with Leonardo. Together, the two teams developed the propulsion system for the world’s first Military Aviation Authority–certified unmanned rotary-wing VTOL aircraft. Achieving certification at that level meant meeting the same exhaustive testing, documentation and compliance standards demanded of manned aviation. Rotron designed a bespoke engine and supported Leonardo through every stage of the airworthiness process.

The outcome was a propulsion system with an unprecedented Time Between Overhaul, combining long endurance with reduced maintenance demand. It set a new benchmark for unmanned platforms, proving they could meet and exceed the highest standards of engineering and compliance.

Rotron’s credentials reinforce that track record, including compliance with U.S. Military Standards, NATO Standardisation Agreements and recent approval for the U.S. Blue List. For defence partners, these assurances mean Rotron systems can integrate seamlessly into current and future battlespace frameworks.

“Partnership is how we move the industry forward,” says Alex Head, CEO. “By working closely with aerospace leaders, we can deliver solutions that meet today’s requirements and anticipate tomorrow’s challenges.”

Shaping the Next Era of Unmanned Aviation

For UAV operators, the future of propulsion is about more than power. It is about what that power enable. Rotron is already investing in hybrid-electric systems that combine the endurance of combustion with the near-silent acoustic and low-emissions profile of electric power. The result is new options for ISR missions that demand discretion and the potential to extend unmanned flight into urban environments where noise and emissions are critical factors.

Rotron’s rise from a garage-born idea to a trusted defence partner underscores how innovation thrives when opportunity is opened to all. Thanks to recent defence reform, Rotron has been able to engage in complex development programmes that were once the exclusive domain of the major primes. In doing so, the company has proven its ability to stand shoulder-to-shoulder with industry giants, delivering cost-effective, agile and novel solutions to some of the most demanding aerospace challenges. For a company built on curiosity and courage, it’s a modern David-and-Goliath story, and the same pioneering spirit that sparked Rotron’s first engine continues to drive the next revolution in unmanned aviation.