Modovolo Co-Founder and CEO Justin Call Discusses the Innovative Bicycle Wheel-Inspired Drone
In a world where high-cost drones with limited flight times are common, Modovolo is breaking the mold with its Modovolo Lift. In this DRONELIFE Exclusive interview, Co-founder and CEO Justin Call shared insights into how this modular, bicycle wheel-inspired drone could offer both extended flight times and affordability. Though still in development, the Lift’s design reflects Modovolo’s commitment to rethinking what drones can do—and how far they can go.
A Drone Inspired by the Bicycle Wheel
“If you look at the Lift Pod, you’re probably thinking it looks like a bicycle wheel. And you’re right,” said Call. He explained that Modovolo drew on the wheel’s lightweight and rugged design. “The bicycle wheel design is an underappreciated technological marvel. It’s super light, strong, and rugged. That’s why we used it as our inspiration for the Lift Pod.”
By mimicking the bicycle wheel, Modovolo was able to reduce the Lift’s weight dramatically. Weighing only 2.5 pounds empty and 7.6 pounds with batteries, the Lift Quad configuration is around 50% lighter than a DJI Matrice 300. But, as Call points out, weight isn’t the only feature that makes the Lift unique.
Key features contributing to flight efficiency include:
- Hub: “We’ve designed the hub so the propeller blades spin at an insanely low RPM, but the motor spins fast. This is very efficient.”
- Rim: The rim acts as a ducted fan, similar to a jet engine, enhancing efficiency and forming the core connection point to other Lift Pods and Utility Pods.
- Propeller Blade: “Our proprietary propeller blade provides the most thrust of any drone out there—and it’s still more efficient than anything on the market.”
- Spokes: “The spokes create amazing structural rigidity, yet they’re virtually weightless.”
According to Call, the result is a drone that achieves up to two hours of flight time on a single charge, a feat that’s rare in the commercial drone world.
Modular Configurations Built for Any Use Case
For Modovolo, the Lift’s modularity is just as essential as its efficiency. “There are truly limitless configurations,” Call shared. He described three primary configurations—Quad, Hex, and Octo—that Modovolo initially selected because they align best with existing flight modes in Ardupilot. Call noted, however, that as Modovolo invests more in software development, the Lift will become even more configurable for specific missions.
The modular design hasn’t come without its challenges. Early prototypes featured rigid structural members, but these were too heavy to allow much flight time. The turning point came when Modovolo’s CTO, Arion, decided to try using spokes, even though he and Call initially had doubts about the idea. “Threading the spokes was a major PIA and took hours,” Call admitted. However, the decision proved pivotal, creating a lightweight structure that finally aligned with the Lift’s design goals.
Achieving Affordability Through Simplicity
With a price point of $6,000, the Modovolo Lift is significantly more affordable than comparable models, such as the DJI Matrice 300. Call attributes this to the bicycle wheel-inspired structure: “It’s rigid, strong, and light without any expensive exotic materials. It’s also a very simple design, and that radically cuts down on manufacturing costs.”
By keeping costs low, Modovolo aims to make the Lift accessible to a broad range of industries. Call explained, “We have a good problem in that the modular and endlessly configurable design means it can be used across all industries and use cases. We haven’t found a single use case it wouldn’t work for.”
Potential Applications in Defense, Agriculture, and Construction
According to Call, the Lift’s design opens doors for applications across various fields. Initially, Modovolo is focused on three core markets:
- Defense: With strategic partnerships in place with large defense contractors, Modovolo sees applications for electronic warfare. “They’ve been looking for long flight time but low-cost platforms because that’s what the DoD wants now,” Call said.
- Agriculture: The Lift’s configuration allows it to handle a wide range of tasks. “In agriculture, we can do everything from surveying to spraying, but right now, we’re focused on niche applications like pollen distribution,” Call shared.
- Commercial Use: Call highlighted that most of the Lift’s pre-orders are from the construction industry, where the drone will support photogrammetry and LiDAR applications. “We’ll have a universal mount Utility Pod so users can add whatever payload they want,” Call said, emphasizing the Lift’s flexibility for different payload needs.
Bringing the Modovolo Lift to Market
Currently, Modovolo is looking for test pilots with experience flying Ardupilot and larger commercial drones to help refine the Lift. “We need pilots who are willing to fly under our testing protocols and give feedback,” said Call. The data from these test flights will guide final adjustments before the first commercial version hits the market.
Future Innovations
Looking forward, Call shared exciting plans for the Modovolo Lift. The team is working on a VTOL variant of the Lift Pod, which will retain the modular design while offering vertical takeoff and landing capabilities. Modovolo is also designing a new game-controller-inspired, NDAA-compliant handset that’s modular and affordable. “We’re all about modularity,” Call added, hinting that Utility Pods designed for specific use cases could be on the horizon.
Challenges and Lessons Learned
Throughout development, the Modovolo team faced obstacles that tested their patience and creativity. “Tuning was a nightmare,” Call shared. The Lift’s unique design meant they couldn’t rely on standard tuning algorithms and had to create their own process, which took months. In another instance, one of their early prototypes melted in the summer heat because it was made from plastic that couldn’t handle temperatures over 85 degrees. “By the time we got to our ‘top secret testing facility,’ it had melted!” Call recalled, laughing.
A Bold New Idea in Drone Design
The Modovolo Lift is still in development, but with its modular, bicycle wheel-inspired design, it promises a new level of adaptability and efficiency for commercial drones. As Call and his team continue refining the Lift, they’re optimistic about its potential across industries, from defense to agriculture. Modovolo’s approach to drone design could reshape expectations around flight time, cost, and functionality in the commercial drone sector.
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