Expo "Flying Car" Demonstration Flights to Resume on July 12 After Three-Month Hiatus ― Investigation into the Cause of the Parts Falling Incident and Implementation of Preventive Measures Completed, Showcasing Japan's Leading Edge in AAM (Advanced Air Mobility) to the World ―

Table of Contents

1. Introduction: The Relationship Between the Expo and AAM

2. What is "HEXA": Overview of the Aircraft and the Developing Company

3. Accident Details: Part Falling on April 26

4. Cause Investigation Process: Analysis and International Investigation Team

5. Preventive Measures: Design Review, Quality Assurance, and Inspection Flow

6. Demo Flight Resumption Plan: Operation Schedule from July 12 to 18

7. Experience Value for Expo Visitors and Perspectives from Foreigners

8. Global eVTOL Trends and Japan's Positioning

9. Current Status and Challenges of Regulations and Infrastructure Development

10. Conclusion and Future Outlook

1. Introduction: The Relationship Between the Expo and AAM

The Osaka-Kansai Expo, opening in April 2025, is the world's first exposition to incorporate actual flights of AAM (Advanced Air Mobility) into its official program, under the theme of "a testing ground for future society." The three daily demo flights attracted attention right from the start, with the hashtag "Expo Sky Show" trending on social media. However, a part falling accident led to a suspension of operations, resulting in the loss of a symbolic content of the Expo.marubeni.com

2. What is "HEXA": Overview of the Aircraft and the Developing Company

HEXA is a single-seat eVTOL developed by Lift Aircraft in Austin, Texas. It features a carbon frame with a diameter of approximately 4.5 meters and 18 independent electric rotors, with a total weight of 196 kg, fitting within the ultralight category under aviation law. It has a battery-swapping system with a maximum flight time of about 10 minutes and a limited altitude of around 50 meters.

It is characterized by a multi-redundant design, such as the ability to land on water with a float structure even in case of capsizing. Marubeni has signed an exclusive sales contract for Japan and is proceeding with operational verification towards practical use.aviationweek.comliftaircraft.com

3. Accident Details: Part Falling on April 26

Around 14:50 on April 26, the left and right motor covers of HEXA fell off while flying over the "EXPO Vertiport" venue. They fell in a restricted area on the opposite side of the spectator area, resulting in no injuries, but the organizers decided to suspend all flights immediately. Marubeni issued an apology that night and began an accident investigation in collaboration with the Ministry of Land, Infrastructure, Transport and Tourism's aviation safety inspector.english.kyodonews.netnewsonjapan.com

4. Cause Investigation Process: Analysis and International Investigation Team

The investigation was conducted by a mixed team of Marubeni, Lift Aircraft, experienced members from the U.S. NTSB, and JCAB. SEM analysis of the aircraft logs and damaged parts was conducted, revealing that the spacer material for the motor cover attachment was ABS resin instead of the aluminum specified in the design.

Furthermore, it was pointed out that the bolt torque on the manufacturing line might have been unmanaged. It was concluded that early loosening due to vibration occurred, leading to detachment due to centrifugal force during flight.news.tv-asahi.co.jp

5. Preventive Measures: Design Review, Quality Assurance, and Inspection Flow

For resumption,

(1) All aircraft will be replaced with aluminum spacers
(2) Torque marking and IoT wrenches will be introduced at fastening points
(3) Pre- and post-flight inspection items will be expanded from 63 to 95
(4) Fail-safe guards considering detachment simulation will be added
(5) Independent third-party inspections will be conducted once a day

These measures have been mandated.
On the 9th, the association monitored a practical test at 30 meters above the venue and judged it to be "no safety issues."newsdig.tbs.co.jpmainichi.jp

6. Demo Flight Resumption Plan: Operation Schedule from July 12 to 18

On the first day of resumption, a functional check flight will be conducted with staff only in the early morning, followed by two unmanned demos in the afternoon. Flights will not be conducted over the audience, and the flight path will be limited to the inside of the sponsor buildings.

From the 13th onwards, the schedule will return to three times a day, with a total of 15 flights evaluated by the 18th. The round-trip flight to Amagasaki City, Hyogo Prefecture, has been postponed as "additional time is needed to ensure ground safety."video.yahoo.co.jp

7. Experience Value for Expo Visitors and Perspectives from Foreigners

At the Expo, English, Chinese, and Korean guides are stationed, and visitors can experience piloting through a VR simulator. Unlike a means of transportation around the pavilion, it is positioned as a "showcase to feel the future of urban air mobility." While eVTOL exhibitions are becoming common in Europe and the U.S., events where actual flights can be seen are still rare, making it a valuable photo spot for foreign tourists.

8. Global eVTOL Trends and Japan's Positioning

Globally, companies like Joby, Archer, and Volocopter are aiming to obtain type certification, but no country has yet entered the "social implementation phase" of mass-produced aircraft. Japan's Ministry of Land, Infrastructure, Transport and Tourism has developed a "roadmap for the revolution of sky mobility," creating one of the most permissive environments in the world for demonstration flights in urban areas.

Osaka Prefecture plans to develop more than 20 urban vertiports by 2025, positioning the Expo as a demonstration platform. The swift resumption after the accident serves as an opportunity to demonstrate the effectiveness of Japanese-style risk management.

9. Current Status and Challenges of Regulations and Infrastructure Development

• Operational Regulations: Currently based on individual permits under experimental application guidelines. The future challenge is to establish a new eVTOL category in line with ICAO Annex 17 amendments.
  
  

• Communication and Control: Securing 5G/6G bandwidth and introducing a U-space-like airspace management system are urgent tasks.
  
  

• Power Infrastructure: Guidelines are needed for the permanent installation post-Expo, including weather resistance of rapid charging facilities and peak demand adjustment.
  
  

• Noise Control: Advancing the disclosure of EPNdB measured value databases for each aircraft to enhance social acceptance of urban operations.

10. Conclusion and Future Outlook

"Flying cars" are set to restart as a "moving showroom" symbolizing the future. The safety design and high transparency in information disclosure following the accident response can be seen as a stepping stone for Japan to take the lead in creating international standards.

HEXA, flying again over the Expo from July 12, is more than just a demo; it heralds the "Year One of AAM." The images captured by visitors on their smartphones will serve as a "postcard" previewing the aerial landscape of the 2030s.

List of Reference Articles (External Links, Chronological Order)

• Mainichi Shimbun "Safety Confirmation Completed for Demo Resumption, Flights Resume on July 12" (2025-07-09) mainichi.jp

• MBS News "Demo Flights Halted Due to Part Falling, Resuming on July 12" (2025-07-08) video.yahoo.co.jp

• TBS NEWS DIG "Test Flights Conducted for Resumption" (2025-07-09) newsdig.tbs.co.jp

• TV Asahi News "Cause of Falling is Specification Error, All Parts Replaced" (2025-07-08) news.tv-asahi.co.jp

• Kyodo News English "Part falls from HEXA, demo flights halted" (2025-04-27) english.kyodonews.net

• Marubeni Corp. "Announces Successful HEXA Demo Flight" (2025-04-15) marubeni.com

• Aviation Week "Marubeni demonstrations of HEXA at Osaka Expo" (2025-04-22) aviationweek.com