Flying a Heavy Drone for Customers? Here's What the FAA Actually Requires

The commercial drone industry is experiencing explosive growth, and nowhere is this more evident than in the heavy-lift sector. From delivering medical supplies to remote locations to transporting critical infrastructure components, drones exceeding 55 pounds are opening new markets and solving real-world problems.

But there's a significant regulatory hurdle: these aircraft fall outside the FAA's Part 107 framework, which only covers drones under 55 pounds. Operating heavier aircraft commercially requires navigating a complex regulatory landscape that many operators find confusing or intimidating.

This guide cuts through the confusion to explain exactly what the FAA requires for commercial heavy-lift drone operations.

The 55-Pound Threshold: Why It Matters

Part 107—the FAA's regulations for small unmanned aircraft systems—has been the regulatory backbone of the commercial drone industry since 2016. It provides a streamlined certification process for operators and clear rules for commercial operations.

However, Part 107 explicitly excludes aircraft weighing more than 55 pounds (approximately 25 kg). This weight limit isn't arbitrary—it reflects safety considerations about the potential damage a falling aircraft could cause and the complexity of operations at larger scales.

Once you exceed 55 pounds, you're operating in a different regulatory regime entirely, one that requires significantly more documentation, planning, and FAA oversight.

Two Primary Pathways for Heavy Drone Operations

The FAA provides two main regulatory pathways for operating drones heavier than 55 pounds commercially:

1. Section 44807 Special Flight Operations

Section 44807 of the FAA Reauthorization Act allows for exemptions to certain regulations for specific operations. This is often the faster, more practical route for many commercial heavy-lift operations.

2. Part 135 Air Carrier Certification

Part 135 certifies operators to carry cargo (and potentially passengers in the future) for hire. This is the same regulatory framework used by commercial helicopter and small aircraft operators.

Let's examine each pathway in detail.

Section 44807: Exemptions for Specific Operations

Section 44807 provides a mechanism for the FAA to grant exemptions from certain regulations when an operator can demonstrate equivalent safety through alternative means.

What 44807 Allows

• Operation of drones over 55 pounds for specific commercial purposes
• Exemptions from certain Part 107 requirements that don't apply to heavier aircraft
• Operations beyond visual line of sight (BVLOS) if safety can be demonstrated
• Night operations with appropriate lighting and safety measures
• Operations over people under certain conditions with proper risk mitigation

Application Requirements

To obtain a Section 44807 exemption, operators must submit detailed documentation including:

Timeline and Process

Section 44807 petitions typically take 6-18 months to process, depending on the complexity of the operation and the completeness of the initial submission. The FAA may request additional information or modifications to the proposed operations before granting approval.

Part 135 Certification: The Air Carrier Route

Part 135 certification is more comprehensive and time-consuming than Section 44807, but it provides broader operational authority and is necessary for certain types of commercial operations.

When Part 135 Is Required

• Scheduled cargo service on regular routes
• On-demand air cargo operations to multiple customers
• Operations requiring extensive BVLOS authority
• Multi-aircraft operations at scale
• Future passenger-carrying operations (when regulations permit)

Certification Requirements

Part 135 certification is a rigorous process that requires:

Timeline and Costs

Part 135 certification typically takes 12-24 months and requires significant investment:

• Documentation development: $50,000-$200,000 depending on complexity
• Demonstration and proving runs: Operational costs for demonstrating compliance
• Personnel: Accountable executives, chief pilot, director of operations, director of maintenance
• Infrastructure: Operational control center, maintenance facilities, training facilities
• Insurance: Significantly higher premiums for Part 135 operations

Alternative Approaches: Experimental and R&D

For operators conducting research, development, or demonstration activities, there are additional options:

Special Airworthiness Certificate - Experimental

Aircraft can receive experimental certificates for purposes including:

• Research and development: Testing new technologies or configurations
• Showing compliance: Demonstrating compliance with airworthiness standards
• Crew training: Training operations for new aircraft types
• Market survey: Customer demonstration flights

Experimental certificates are faster to obtain but come with operating limitations, including restrictions on commercial operations and geographic boundaries.

Key Safety Requirements Across All Pathways

Regardless of which regulatory pathway you pursue, certain safety requirements are universal:

Airworthiness

The aircraft must be designed, built, and maintained to appropriate standards. This typically requires:

• Design documentation and engineering analysis
• Build quality control and inspection records
• Regular maintenance and inspection programs
• Continuing airworthiness monitoring

Command and Control (C2) Links

Reliable communication between the pilot and aircraft is critical:

• Redundant systems: Multiple communication pathways
• Link budget analysis: Demonstrating adequate signal strength
• Interference mitigation: Handling of signal degradation or loss
• Lost link procedures: Automated responses to communication failure

Detect and Avoid (DAA)

Heavier drones must have means to detect and avoid other aircraft:

• Visual observers: Trained personnel maintaining visual contact
• Electronic detection: ADS-B, radar, or other surveillance systems
• Automated avoidance: Systems that can autonomously avoid conflicts
• Air traffic coordination: Integration with ATC systems

Risk Mitigation

Comprehensive risk analysis must address:

• Ground impact risk: Probability and consequences of aircraft failures
• Third-party risk: Risk to people and property on the ground
• Airspace risk: Risk to other aircraft
• Environmental risk: Noise, pollution, wildlife interactions

Pilot Requirements for Heavy Drone Operations

Operating heavy drones commercially requires more than a Part 107 license:

Minimum Qualifications

• Part 107 remote pilot certificate as a baseline
• Aircraft-specific training for the systems being operated
• Emergency procedure training including lost link, system failures, and emergency landing procedures
• Regulatory knowledge of the specific exemption or certificate operating limitations

Additional Certifications

Depending on the operation, pilots may also need:

• Manned aircraft pilot certificate (for certain Part 135 operations)
• Instrument rating (for operations in instrument meteorological conditions)
• Type-specific ratings for complex aircraft
• Medical certificates (required for some Part 135 operations)

Insurance and Liability Considerations

Insurance providers will evaluate:

• Aircraft weight and kinetic energy
• Operating environment (urban vs. rural)
• Pilot experience and training
• Safety systems and redundancy
• Operations manual and safety procedures
• Claims history and safety record

Practical Steps to Get Started

If you're planning commercial heavy-lift drone operations, here's a practical roadmap:

Step 1: Define Your Operations

Clearly articulate:

• What cargo or payload you'll carry
• Where you'll operate (geographic area, airspace classes)
• How often operations will occur
• What altitudes and distances are required
• Whether BVLOS or night operations are needed

Step 2: Determine the Right Pathway

Consult with FAA representatives or aviation attorneys to determine whether Section 44807 or Part 135 is appropriate for your operations. Consider:

• Scale of operations
• Frequency and regularity
• Customer base
• Long-term business goals
• Available resources and timeline

Step 3: Develop Documentation

Begin developing the required manuals, procedures, and safety documentation. This is typically the most time-consuming phase and may require:

• Aviation consultants with regulatory experience
• Technical writers for operations manuals
• Safety analysts for risk assessments
• Engineers for airworthiness documentation

Step 4: Engage with the FAA Early

Schedule pre-application meetings with the FAA to:

• Discuss your proposed operations
• Understand current FAA priorities and concerns
• Get feedback on your approach
• Establish points of contact for questions

Step 5: Submit and Iterate

Submit your petition or application, then be prepared to:

• Respond to questions and requests for additional information
• Modify procedures based on FAA feedback
• Conduct demonstration flights if required
• Participate in formal meetings or presentations

Common Pitfalls to Avoid

The Future of Heavy Drone Regulation

The regulatory landscape for heavy drones continues to evolve. Current developments include:

• Type certification pathways: FAA developing streamlined type certification for unmanned aircraft
• BVLOS frameworks: New rules for routine beyond visual line of sight operations
• Urban air mobility: Regulations for passenger-carrying electric vertical takeoff and landing (eVTOL) aircraft
• Automated systems: Frameworks for increasingly autonomous operations
• Remote identification: Enhanced tracking and identification requirements

Operators should stay engaged with industry working groups and FAA rulemaking processes to influence and prepare for coming regulatory changes.

Conclusion: Challenging but Achievable

Operating drones heavier than 55 pounds commercially is significantly more complex than Part 107 operations, but it's entirely achievable with proper planning, documentation, and persistence. The key is understanding that you're not just flying a bigger drone—you're entering a different tier of aviation with correspondingly higher safety standards and regulatory oversight.

Success requires:

• Realistic timeline expectations
• Adequate budget for documentation and compliance
• Strong safety culture and risk management
• Professional-grade operations manuals and procedures
• Qualified personnel throughout the organization
• Ongoing compliance monitoring and improvement

The commercial opportunities for heavy-lift drones are substantial and growing. Operators who invest in doing things properly—with comprehensive safety systems, professional documentation, and genuine commitment to regulatory compliance—will be positioned to lead this emerging market.

"The FAA isn't trying to prevent heavy drone operations—they're trying to ensure they happen safely. Meet them halfway with professional documentation and genuine safety analysis, and you'll find them to be reasonable partners in the certification process." — Industry Aviation Consultant

Whether you choose Section 44807 exemptions or full Part 135 certification, the path forward starts with understanding exactly what the FAA requires and building your operation to meet those standards from day one.