HENNIKER, N.H. — Hector Xu’s early challenges navigating night flights during helicopter training in college sparked an idea that could transform agriculture and disaster relief. Now the founder of Rotor Technologies, Xu is at the forefront of unmanned aviation with the Sprayhawk, an unmanned helicopter designed for agricultural and industrial applications.
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Rotor Technologies, founded in 2021, has built two Sprayhawk helicopters and plans to launch as many as 20 by next year. These autonomous helicopters have the potential to revolutionize industries such as crop spraying, cargo transport to disaster zones, offshore logistics, and even wildfire suppression.
On Wednesday, the company will conduct a public flight test of the Sprayhawk at an agriculture aviation trade show in Texas, marking a significant milestone for the startup.
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A Safer Alternative for Agriculture
The agriculture sector, which has widely adopted drones, is now eyeing unmanned helicopters as a way to handle larger-scale operations. Unlike drones, Sprayhawk helicopters can carry heavier payloads and cover extensive areas, making them an efficient solution for pesticide and fertilizer spraying.
“People kept asking if we could use this for crop dusting, and we realized it’s a huge untapped market,” Xu said. The Associated Press witnessed a Sprayhawk test flight, showcasing its ability to hover, spray, and land autonomously.
Rotor’s Sprayhawk, based on a Robinson R44 model, has been extensively modified. Its four seats have been replaced with advanced flight computers, communications systems, cameras, laser sensors, radar altimeters, GPS, and motion sensors to enhance terrain navigation, even at night.
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Addressing Safety Concerns in Crop Dusting
Crop dusting remains one of the most hazardous professions in aviation. Pilots fly at low altitudes—around 10 feet above ground—at speeds of 150 mph, often encountering obstacles like powerlines, cell towers, and other aircraft. Between 2001 and 2010, the National Transportation Safety Board reported over 800 agricultural aviation accidents, including 81 fatalities. More recent data shows 640 accidents and 109 fatalities since 2014.
“It’s a very dangerous profession with multiple fatalities every year,” said Dan Martin, a research engineer with the U.S. Department of Agriculture. Long work hours and exposure to chemicals further compound the risks.
Unmanned aircraft like the Sprayhawk offer a safer alternative, reducing human exposure to these dangers.
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A Growing Market for Autonomous Aviation
The demand for autonomous aircraft in agriculture is surging. While drones have become popular for smaller fields, their limited size and battery life restrict their capabilities compared to larger unmanned systems.
California-based Pyka has also entered the market with its Pelican Spray, an autonomous fixed-wing aircraft. Pyka’s electric plane received FAA approval for commercial crop protection last year and has secured clients such as Dole and Brazil’s SLC Agrícola.
Lukas Koch, Chief Technology Officer at Kansas-based Heinen Brothers Agra Services, emphasized the potential of autonomous systems to improve safety. While he doesn’t see unmanned aircraft replacing all pilots, they could take on the riskiest jobs, such as spraying fields surrounded by trees or power lines.
“The biggest draw is taking the pilot out of those most dangerous situations,” Koch said.
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Navigating New Challenges
Despite their benefits, autonomous systems bring new challenges to aviation. “Adding unmanned systems to the airspace could introduce risks for existing pilots,” Koch noted. In rural areas with fewer obstacles, however, the risks are minimized.
Rotor Technologies has implemented multiple safety measures. The Sprayhawk features redundant communication systems and a failsafe mechanism—a “big red button” that allows operators to remotely shut off the engine and perform a controlled landing in case of emergencies.
“We’ll never have an aircraft fly-away event,” Xu assured.
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Scaling Up for a Global Market
Rotor Technologies is working toward FAA regulatory approval, a critical step for commercial operations in the U.S. Once approved, the company aims to scale production to meet growing demand domestically and internationally, particularly in agriculture-heavy markets like Brazil, where regulations are less stringent.
“I think 2025 will be production hell, as Elon Musk calls it,” Xu said, referencing the challenges of scaling production. “We’re moving from bespoke, Rolls-Royce-like builds to mass production, like automobiles.”
As Rotor Technologies pioneers this new frontier, its innovations promise to reshape industries and redefine safety and efficiency in aviation.
