What if drones could deliver essential supplies to our army easily at the highest peaks, in extreme cold, and operate reliably where no vehicle has gone before? An urgent issue that needed to be solved, says Gaurav Achha from BonV Aero. EFY’s Vidushi Saxena listens to the story behind their drone tech.
Q. Can you please explain what BonV Aero does in simple words?
A. BonV Aero is an Indian research and development (R&D) company based in Bhubaneswar and Delhi that designs, engineers and manufactures heavy-lift aerial mobility platforms; drones built to transport large cargo loads in extremely challenging conditions. These platforms are primarily developed for the Indian Army, which operates across harsh terrain such as Leh, Ladakh, Tawang and Siachen at altitudes of 3048 to 5486 metres (10,000–18,000 feet), where soldiers still rely on mules to carry essentials like kerosene, rations and ammunition. You see, our drones are designed to carry heavy payloads at high altitudes. They also offer disaster-relief potential, enabling emergency delivery of medical aid, equipment and support during floods or similar crises. Commercial applications include logistics support in hilly pilgrimage regions like Kedarnath, Amarnath and Gannavaram Jain Tirth, along with maritime and other niche sectors. We handle the end-to-end development process, from engineering and system integration to manufacturing, ensuring our platforms meet stringent aviation standards and operate safely in the demanding Himalayan environment.
Q. What inspired the founding of BonV Aero?
A. BonV Aero was founded with the ambition to introduce smart aerial mobility to India, addressing mobility gaps in hilly and remote areas where road and air networks fall short. The original idea was to develop electric aerial vehicles for short-distance passenger transport. However, during early development, we identified a more urgent need: the severe logistical challenges faced by soldiers in the Himalayas. This led us to begin our journey with heavy-lift electric logistics platforms tailored for defence operations. Building these solutions created a strong technological base for our long-term goal of developing transport-class electric aerial vehicles for human passengers, capable of enabling clean, efficient 20–50 km commutes for both urban and regional mobility. The company was inspired by the idea of using cutting-edge engineering to solve real-world mobility challenges.
Q. Can you tell me about your product portfolio?
A. Yes. Our hero product, the Air Uttam, has set a world record for lifting a 30-kilogram payload at the highest motorable place in the world, Umlingla, Ladakh, at 5800.6 metres (19,024 feet). Our flight software, again, is highly adaptive, the airframe is lightweight yet robust, and our propulsion system is optimised for high-altitude performance. The powerplant consists of high-energy-density battery packs with thermal management to operate reliably at temperatures as low as minus 40 degrees Celsius. We are innovating in smart charging and battery management. Our smart charging system ensures battery longevity, safety and extended operational lifespan.
Q. Is the product just in the development stage, or is it in the market?
A. The product is already in the market. Our logistics platform, Air Orcaa, has been supplied to the Indian Army’s Northern Command and is in active commission. We have trained over 100 soldiers, and these drones operate at high-altitude locations in Ladakh. We have deployed a double-digit number of drones across these divisions and are working with the Army to supply hundreds more platforms.
Q. What is the heaviest weight that your drones can carry at this point in time?
A. We have demonstrated a 50-kilogram payload at 5486 metres (18,000 feet) for the Indian Army. Our drones can carry up to 100 kilograms and, depending on operational requirements, up to 200 kilograms. Payload capacity and range are interdependent; the exact operational envelope depends on mission requirements.
Q. How do your drones fly in high mountains where the air is thin?
A. It is extremely challenging, flying at high altitudes, I mean, because air density drops to about one-fourth of what it is at sea level. Just as humans sometimes need oxygen cylinders in such conditions, propellers also struggle to generate enough thrust in thin air. Propellers work by pushing air downwards to create lift. At high altitudes, because the air is thinner, the drone needs to move more air at higher RPMs to achieve the same thrust. However, torque and RPM are inversely related, so generating sufficient thrust becomes a technical challenge.
Q. What safety features do your drones have?
A. Our drones are large, heavy-lift platforms with dimensions around 365.8 centimetres by 365.8 centimetres (12 feet by 12 feet) and a maximum take-off weight of approximately 230 to 240 kilograms. We use a distributed electric propulsion system, which keeps the drone stable even if one motor fails. Our adaptive flight software optimises performance based on payload and weather conditions. Even in the event of multiple failures, the drone has a ballistic parachute for controlled descent. We follow rigorous standard operating procedures before every flight.
Q. Do these drones also use artificial intelligence (AI)?
A. They do. One key AI application is predictive maintenance, and let me explain to you that. Each drone has a unique vibration signature. By monitoring these signatures, machine learning (ML) algorithms detect deviations to predict potential issues. We also use computer vision for detecting and identifying objects in fog or low visibility, enabling obstacle avoidance and precision landing.
Q. How are your drones different from the drones used for photography?
A. They are fundamentally different. Our drones are battle-tested at high altitudes in the Himalayas, capable of flying at around 5486 metres (18,000 feet) while carrying cargo. Photography drones are designed for light payloads, whereas ours are aerial mobility platforms built for logistics, defence and extreme environments. They operate from minus 20 degrees Celsius to plus 50 degrees Celsius and withstand low air density and gusty winds.
Q. Do you also export these products, or are they only for India right now?
A. We are open to exports and in discussions with the United States Department of Defence (US DoD), including the Defence Innovation Unit (DIU), as well as Saudi Arabia, Bahrain and others. BonV Aero has been selected to join the Unmanned Aerial Systems Heavy Lift Capability (UASHLC) Framework led by the United Kingdom Ministry of Defence (UK MoD) under its Future Capability Innovation division.
Q. Can you explain the technical challenges of operating UAVs at extreme altitudes and how your team overcomes them?
A. Operating unmanned aerial vehicles (UAVs) at extreme altitudes is challenging due to thin air, low temperatures and harsh terrain. Our team spends months stationed in remote environments to commission and test drones. High-altitude operation requires specialised propulsion systems, adaptive flight software and robust design. We address these through empirical testing and on-site engineering. We aim to make India a hub for electric vertical take-off and landing (eVTOL) and advanced aerial mobility technology. Our global vision is supported by international investors, including Tim Draper.
Q. Do you also collaborate with research institutes or defence organisations on technical development?
A. We collaborate with the Defence Research and Development Organisation (DRDO), Tata Institute in Bangalore, Indian Institute of Science (IISc), Indian Institute of Technology (IIT) Kharagpur, IIT Mandi, IIT Bhubaneswar and AICCV Raman Global University. Our 7000 square feet (650.3 square metres) R&D space in Bhubaneswar includes an anchored test facility. These collaborations involve additive manufacturing, computer vision, power electronics and communication resilience, including GPS-denied and jamming-resistant technology.
Q. What kind of talent do you look for when hiring engineers?
A. We hire across disciplines, including electric vehicle (EV) engineering, automotive, robotics and electronics. We recruit fresh graduates, PhD researchers and business school talent. We also offer internships.
Q. Do you also have your own manufacturing?
A. We conduct small-scale manufacturing of up to 100 units at our facility in Bhubaneswar. We have partnered with a defence public sector undertaking (PSU) and received approval from the State of Odisha to develop a 5-acre (2.02-hectare) Drone Mobility Park to scale manufacturing.
Q. Can you tell me about your investment and partnership with various state authorities?
A. BonV Aero was founded by six co-founders led by our CEO Satya Satyapati, and CTO Abhinash Sahu, a certified pilot. NITI Aayog recognised us, showcased at VivaTech in Paris and received early-stage funding from angel investors and IITs. We raised a Seed/Series A round from Beyond Ventures and Inflection Point Ventures. In January 2024, we won Global Meet the Draper Season 6, earning an investment from Tim Draper. In May 2024, we closed another round with Unicorn India Ventures and Udyat Ventures.
Q. How do you think the government is helping you?
A. The government reduced the goods and services tax (GST) on drones to 5%. The Drone Policy 2021 and the Digital Sky platform simplified approvals. The production-linked incentive (PLI) scheme with an allocation of ₹1.2 billion, boosted manufacturing. The Drone Didi initiative signals strong strategic support too.
Q. How do you see BonV Aero evolving over the next 5 years?
A: We see BonV Aero leading innovation in aerial mobility and defence drones. There is increasing demand from the Indian Army across tactical and non-tactical applications. The global drone industry could reach $100 billion within five years. We are also building India’s first Drone Mobility Park in Odisha to support large-scale manufacturing, testing and innovation. We aim to lead the transformation of India’s aerial mobility ecosystem.
