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Hydrogen Electric Solutions

Aviation Engineering Services

Guiding the Future of Clean Flights

PowerCell Group is your partner in developing the next-generation zero-emission powertrain for any type of aviation. With our market-leading power density, we can support a wide range of applications, from drones to fixed-wing aircraft. Based on our extensive experience in assisting customers with their integrations, we have developed a methodology that guides you through all phases of the project — from analysing the mission profile to product development based on our hydrogen fuel cell technology.

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Fast Track to Zero-Emission Aviation

We are dedicated to making the transition to hydrogen electric flights as seamless and efficient as possible

Minimise Technical Risk

With decades of experience in the fuel cell industry, we proactively identify and mitigate potential challenges to ensure a reliable and efficient implementation. Our solutions are already airborne, offering you proven technology that minimises technical risks and maximises operational success.

Minimise R&D Investment

Our consultancy services deliver an optimised fuel cell solution tailored to your specific needs, significantly reducing your initial R&D investment. By leveraging our labs, testing capabilities, products and expertise, you can avoid the high costs and uncertainties of extensive research and development.

Minimise Time to Market

We accelerate your transition to zero-emission aviation, shortening the time to market. Our streamlined processes and proven methodologies ensure that you can start benefiting from cleaner, more sustainable power solutions without unnecessary delays.

Step by Step Towards Sustainable Aviation with PowerCell Group

We are dedicated to supporting your journey towards zero-emission aviation through the use of hydrogen fuel cells, guiding you every step of the way towards take-off. Our involvement will depend on your specific needs throughout the project until we achieve your customised solution.

1. Feasibility Stage

We offer in-depth support during the feasibility stage, addressing preparatory questions and laying the foundation for your project.

2. Concept Development

Our engineers optimise the integration with existing aviation systems, using stakeholder input and preliminary testing to refine the concept.

3. Product Development

Refining the prototype through rigorous testing and validation, ensuring it meets stringent performance and safety standards.

4. Product Release

Finalising documentation and certification with aviation authorities, guaranteeing full compliance with regulatory requirements.

5. Pre-Production

We establish production lines, conduct pilot runs, and implement quality control measures to ensure the reliability of the final product.

Case Study

Safe and Green Flights with
Redundant Fuel Cell Systems

Background

As the aviation industry faces growing scrutiny on its share of climate warming emissions and combustion alternatives come with clear downsides, true zero-emission flight with fuel cells is becoming a major focus. After completing 15 test flights with a one-engine plane, ZeroAvia is now conducting more advanced tests with a two-engine air- craft and redundant propulsion systems. When ZeroAvia’s 19-seater Dornier 228 twin-engine aircraft completed a 10-minute test flight in January 2023, it was the largest aircraft to have made a successful flight using a hydrogen-electric powertrain, with PowerCell fuel cell stacks as a core part of the system.

Scope

Our fuel cell expertise and ZeroAvia’s aviation experience are perfect for integrating a fuel cell system into an aircraft.

  • Robust and compact fuel cell adapted for aviation.
  • A load-following system – reacting faster than a jet engine.
  • Application-specific software.
  • Risk evaluation.

Challenges & Solutions

In comparison even to heavy-duty road transport, the importance of weight in aviation is exponentially higher. The fuel cell powertrain needs to have a high enough power/weight ratio to meet peak power requirements. ZeroAvia selected our technology because of its leading energy density and both organisations are partnering to optimise the weight of the system in the pathway to a final certifiable design.

Robust and Compact Fuel Cell System

We have designed a compact fuel cell system that is easy to integrate and provides a high power/weight ratio. The fuel cell uses hydrogen gas and oxygen from the air to produce electricity, emitting only heat and water vapor, which must be efficiently rejected from the plane. The solution is proven in harsh environments and has proven its durability and power output through extensive ground and flight tests.

Redundancy in Propulsion Systems

In aviation, safety goes before optimisation, and two redundant propulsion systems in ZeroAvia’s testbed aircraft ensure double levels of safety. Batteries on board also provide redundancy and an extra power source at takeoff and rejected landings, where an instant increase in power is needed. With the help of a rigorous diagnostic system, We have validated the system redundancy and avoided several sources of single point failures.

A Load-Following System & Application Specific Software

The hydrogen-electric system is faster than a jet engine to ramp up the power when needed, which makes it not only the best way to decarbonise but a superior propulsion system overall.

We have developed specific software to meet ZeroAvia’s needs in terms of the application specification and risk management. For example, a control logic software to get maximum instant power outtake at rejected landings, when the plane needs to regain altitude fast.

P System 100

The P System 100 enables durable and flexible use, with an electric output of up to 100 kW. The system is specifically designed to accomplish compact integration together with a high power output and has a robust construction.

Download Data Sheet
PowerCell Group Hydrogen Fuel Cell System P System 100

Partner with Us for a Sustainable Future

Contact us and start the journey towards cleaner skies today