Author: Dominic Weeks

[Everett, WA & Kemble, UK: 11th March 2025] — ZeroAvia today announced that its SuperStack Flex highly-customizable LTPEM fuel cell architecture has achieved over 1.0kW/kg specific net power at a full system level, including thermal management system, and has been successfully demonstrated in a 150kW net power configuration for a major customer.  

The industry leading testing results have been made possible thanks to ZeroAvia’s innovative use of additive manufacturing techniques and will expand UAV / VTOL capabilities of the systems, as well as opening new applications in aerospace and other sectors.  

Using selective laser sintering (SLS) powder-bed additive manufacturing processes, ZeroAvia has been able to perform high velocity cycles of design, build and test, and quickly combine typical parts or their functions into new monolithic structures. The key parts in the SuperStack Flex’s balance of plant – Anode, Cathode and Coolant Manifolds, thermal management, humidification and air compression systems – have been reduced from over 200 parts to less than 100, with ~50% weight and volume reductions. Fewer parts mean lighter, more compact, more reliable and less costly systems.   

The ZeroAvia SuperStack Flex is a modular fuel cell power generation platform that can be scaled up or down between 100kW and 600kW net total continuous power applications. The lightweight, aviation optimized balance-of-plant, has been developed as a best-fit approach for many Unmanned Air Vehicles (UAV) with further potential applicability across aerospace and in marine and ground vehicles.  

As well as its flexibility for different power requirements, the SuperStack Flex design enables separation of the core systems, meaning it can be highly versatile and efficient to integrate into different airframes, overcoming space constraints.  

The flexibility of the SuperStack Flex system enables customers to incorporate the technology and accelerate their R&D on fuel cell powered platforms. ZeroAvia’s focus on certification of its fuel cell engines and its traction with the CAA and FAA, provides confidence to customers working towards regulatory approval of their platforms. 

[Everett, WA: 18th February 2025] — ZeroAvia today announced that it agreed a deal for the first sale of its 600kW electric propulsion system (EPS) to Jetcruzer International for electric flight testing to hone the design of its Jetcruzer 500E. Delivery of the development unit EPS is expected this spring.  

ZeroAvia has secured well in excess of 2,000 pre-orders for its full hydrogen-electric powertrains from commercial airlines and last year the company launched  a component offering to serve the market for novel electric air transport applications.  

ZeroAvia’s 600kW EPS has just received an FAA G-1 issue paper outlining the basis of certification. The system comprises the company’s proprietary inverter and electric motor technology to deliver a highly efficient electric engine with exceptional fault tolerance and specific power. The 600kW EPS system comprises four ZeroAvia 200kW continuous power bidirectional inverters converting DC power to AC to supply ZeroAvia’s direct drive motor, capable of 2,200 rpm.  

ZeroAvia has opened a 136k sq ft Propulsion Center of Excellence in Everett, WA to produce the electric propulsion systems for its own full hydrogen-electric powertrains and for aircraft OEMs like Jetcruzer.  

Jetcruzer International is developing the Jetcruzer 500E, a six-seat hydrogen-electric aircraft, with an entry-into-service target of 2028, followed by the 1250E in 2030. ZeroAvia’s EPS system will be integrated into flight testing using a redesigned and rebuilt Jetcruzer 500 as a testbed for the new electric aircraft. Originally conceived in the 1990s as a cost-effective air transport solution, the Jetcruzer 500 achieved significant FAA certification milestones but never reached production. Jetcruzer International acquired the intellectual property in 2017 and has since been dedicated to advancing a new era of sustainable aviation. 

The Jetcruzer 500E is set to become one of the first aircraft with a type certificate to successfully fly with an all-electric propulsion system. This collaboration with ZeroAvia underscores Jetcruzer International’s dedication to innovation and environmental responsibility. 

[Kemble, UK: February 4th, 2025] — ZeroAvia today announced that it has been invited to join the UK Civil Aviation Authority’s extended and expanded Hydrogen Challenge programme.  

Working with the CAA, ZeroAvia will explore the necessary safety and regulatory requirements for commercial adoption of hydrogen as it looks towards the certification of its ZA600 hydrogen-electric powertrain for up to 20 seat aircraft. This work with the regulator includes exploring safe hydrogen fuel storage, distribution and refuelling practices at airfields and on aircraft. It complements ZeroAvia’s efforts to certify its first full hydrogen-electric engine – the ZA600 designed for up to 20 seat planes – with the CAA.  

ZeroAvia’s participation in the first round of the Sandbox Challenge included investigating the development, design & testing of the ZA600, and furthering the operational understanding and safety requirements of hydrogen in aviation.  

The next stage of the Hydrogen Challenge will see the development of new designs of cutting-edge aircraft that use hydrogen fuel cell power systems and remotely piloted systems to drive down carbon emissions. It will also examine changes to airport infrastructure, include new scientific research by some of Britain’s leading aeronautical institutes, and support flight trials, safety assessments, and demos.  

[Everett, WA: February 3rd, 2025] — ZeroAvia today announced that it has reached consensus on the Certification Basis relating to its 600kW electric propulsion system (EPS) with the Federal Aviation Administration (FAA), having received a G-1 Issue Paper (stage 2) and formally confirmed agreement with its contents. 

The G-1 represents a key milestone on the journey towards final certification of the company’s EPS with the U.S. regulator, and also on its path to certifying its first full hydrogen-electric powertrain (of which the EPS is a core system) with the UK Civil Aviation Authority. The issue paper designates the applicable airworthiness regulations specific for ZeroAvia’s EPS, allowing the company to validate its design requirements.  

ZeroAvia’s 600kW EPS combines the company’s proprietary inverter and electric motor technology to deliver a highly efficient electric engine with exceptional fault tolerance and specific power. The 600kW EPS system comprises four ZeroAvia 200kW continuous power bidirectional inverters converting DC power to AC to supply ZeroAvia’s direct drive motor, capable of 2,200 rpm. Potential applications for the 600kW EPS include battery, hybrid and fuel cell electric fixed-wing aircraft, rotorcraft and Unmanned Aerial Vehicles.  

The 600kW system was designed as part of ZeroAvia’s wider ZA600 hydrogen-electric powertrain, designed for up to 20 seat commercial aircraft. By advancing the aerospace applicability and performance of power electronics and electric motors, the company is progressing discussions to supply the electric propulsion system separately to other clean aviation innovators. Last year ZeroAvia opened a 136k sq ft Propulsion Center of Excellence in Everett, WA to produce these electric propulsion systems.   

The electric propulsion system is one part of the company’s deep portfolio of fuel cell, power electronics and electric motor technology developed thanks to a strong commitment to vertical integration, and ZeroAvia launched a component offering to serve the market for novel electric air transport applications in May 2024. 

[Everett, WA; January 15, 2025] — ZeroAvia, a leader in developing zero-emission propulsion for aviation, has been named on Cleantech Groups 2025 Global Cleantech 100. This annual list, now in its 16th year, showcases the most promising private cleantech companies making significant contributions to sustainable innovation.

The complimentary report will introduce you to the innovators advancing groundbreaking technologies and business models to enable us to act on the ever-increasing climate and environmental crisis.

The cleantech theme is poised for pivotal milestones in 2025 as market forces intensify and innovation accelerates. Continuing trends from 2024, including policy uncertainty, groundbreaking first-of-a-kind (FOAK) projects, and the surging demand for climate adaptation technologies, will emphasize the importance of product and project economics.

Companies that capitalize on organic demand—such as the growing needs of data centers—and prove their technologies in real-world environments without relying on favorable policy support, will find themselves in the best position to succeed. Economic viability will be the defining metric of success in 2025.

[Kemble, UK and Everett, WA, USA: October 29, 2024] — ZeroAvia today announced that it has signed a new Memorandum of Understanding (MOU) with PowerCell Group to collaborate on next generation fuel cell technologies. Joint R&D will focus on intermediate and high temperature fuel cells which will open up more energy intensive applications such as large fixed-wing aircraft and rotorcraft.

The two companies have been working together for the last few years, with PowerCell fuel cell stacks forming part of the prototype ZeroAvia powertrains that have powered both of the breakthrough fuel cell flight demonstrators flown by ZeroAvia.

ZeroAvia is designing a bespoke multi-stack balance-of-plant architecture using PowerCell’s low temperature proton exchange membrane (LT-PEM) stacks applicable to aviation applications. As such, the Swedish fuel cell manufacturer is a key supplier for ZeroAvia’s first 600kW powertrain (ZA600) designed for up to 20 seat aircraft.

ZeroAvia’s high temperature PEM fuel cell (HT-PEM) stacks – part of the roadmap to delivery of ZA2000 powertrain for 40-80 seat aircraft and a key part of the company’s component offering to other clean flight innovators – are already demonstrating industry record power density in excess of 2.5 kW/kg at the cell level, with a clear pathway to reaching 3+ kW/kg at the system level in the coming months.

Increasing the operating temperature of fuel cell systems can allow for a reduction in cooling and humidification required, simplifying the architecture and improving the amount of power for a given unit of weight.   

The collaboration will leverage PowerCell’s long experience industrializing hydrogen-electric technologies to push advanced fuel cells solutions to high TRL levels. For ZeroAvia, it will provide the opportunity to exploit its technology in different sectors, while retaining its core focus on aerospace.

[Kemble, UK and Everett, WA: October 10th 2024] – ZeroAvia today announced that its HyFlyer II project has been chosen as Project of the Year 2024 by the UK’s Aerospace Technology Institute (ATI). The award celebrates projects funded through the ATI programme that have reached a significant milestone or concluded within the last year.  

The HyFlyer II programme, which ran from December 2020 to November 2023, has created hundreds of jobs, large inward investment and world-first breakthroughs. In Kemble, UK, January, 2023, ZeroAvia showcased the first flight of a retrofitted 19-seater twin-engine Do228 hydrogen-electric testbed.  

The flight testing and system development as part of HyFlyer II has been critical in designing and testing fuel cell and electrical-propulsion systems, establishing greater confidence in the potential for zero-emission flights this decade and leading to what could be the world’s first certified hydrogen-electric engine for commercial aircraft. ZeroAvia has already submitted its application to certify the ZA600, 600kW hydrogen-electric powertrain for up to 20 seat aircraft to the CAA.

The project also involved the development of novel high-temperature proton exchange membrane (HTPEM) fuel cells for aviation, exhibiting technology readiness for scaling hydrogen-electric technology for large aircraft. ZeroAvia sees HTPEM fuel cell power generation as key to developing zero-emission propulsion systems for aircraft larger than 20-seats, and the technology is integral to the company’s ZA2000 2-5.4 MW engine for 40-80 seat planes. Hydrogen-electric engines use hydrogen in fuel cells to generate electricity, which is then used to power electric motors to turn the aircraft’s propellers – the only emission is water.  

ZeroAvia’s presence in the UK continues to grow with expansion of its operations, leading testing capabilities, including back-to-back electric propulsion rigs and fuel cell test labs, flight test platforms and hydrogen production at airport as well as associated refuelling infrastructure. 

HyFlyer II has positioned ZeroAvia well to unlock the market for large regional turboprops, regional jets and, ultimately, the narrow-bodied aircraft segment, as well as supporting the growth of the UK supply chain, hydrogen economy and advancing the pathway for manufacturing. ZeroAvia has also launched a component line to support other electric aviation innovators based on the development for its full powertrains, further broadening the market for the technology. 

[Hollister, CA: September 12th 2024] — ZeroAvia today announced that it has extended its Series C financing to a total of $150m, with a £20m investment from Scottish National Investment Bank (“the Bank”) coming alongside recent investments from American Airlines, International Airlines Group (IAG) and ITOCHU Corporation.  

The round was co-led by Airbus, Barclays Sustainable Impact Capital and NEOM Investment Fund (NIF), with UK Infrastructure Bank joining as a cornerstone-level investor, and with strong support from existing shareholders including Breakthrough Energy Ventures, Horizons Ventures, Ecosystem Integrity Fund, Summa Equity, Alaska Airlines, Amazon’s Climate Pledge Fund and AP Ventures.  

This is the Bank’s first investment in hydrogen-based technology and the sustainable aviation sector and will bolster the burgeoning aerospace supply chain in Scotland as ZeroAvia looks to create a manufacturing facility in the country. 

ZeroAvia has already extensively flight tested a prototype of its first ZA600-engine aboard a Dornier 228 aircraft at its UK base and the application for certification is underway with the CAA. The company has also performed advanced ground tests in the US and UK for the key building block technologies for the ZA2000 system, including cryogenic tanks for LH2 and proprietary high-temperature PEM fuel cell and electric propulsion systems. ZA2000 will support up to 80 seat regional turboprop aircraft such as the ATR72 and the Dash 8 400. The company is also selling its component technology, including electric motors and fuel cell power generation systems, to other electric aviation innovators.  

[@Farnborough Airshow: July 26th, 2024] –  Ecojet, the world’s first electric, commercial airline, has signed an agreement to purchase 22 ZA2000 hydrogen-electric engines from the zero emissions innovator ZeroAvia, with options for a further 40 engines. The order takes the world a step closer towards a revolution in aviation with carbon free flights. The ZA2000 engine can be retrofitted into 40-80 seat regional turboprops for zero-emission flight.  

The agreement deepens the commitment announced last November 2023, with a deposit schedule that will ensure Ecojet secures some of the first production slots of ZeroAvia ZA2000 powertrains post certification. 

Ecojet based in Edinburgh is aiming to be the industry’s first fully electric commercial carrier enabling carbon-free living. The airline is aiming to launch services in late 2024 with conventionally powered aircraft, operating routes to and from Edinburgh and retrofitting them once the technology is certified. 

The airline will begin this journey by operating its first zero-emission aircraft with ZeroAvia’s ZA600 engines for up to 20 seat planes. Ecojet’s aim is to build a fleet of larger regional aircraft to serve passengers on key domestic and shorter international routes. 

The innovative hydrogen-electric engines work by using hydrogen to generate electricity which then powers propellers to fly the aircraft. 

@Farnborough Airshow — ZeroAvia today announced that it has been awarded £10.5 million in UK Government funding through the ATI strategic programme, to further develop its high temperature fuel cell technology, a promising pathway for delivering zero-emission propulsion systems up to and including narrowbody jets.  

The Advanced Fuel Cell for Aviation Decarbonisation (AFCAD) project will see ZeroAvia collaborate with the University of Kent, Coventry University and the University of Sheffield Advanced Manufacturing Research Centre, to advance this crucial technology towards commercialisation. The research will centre on developing components and the full HTPEM stacks and demonstrating previously unmatched levels of specific power and durability.  

AFCAD builds on ZeroAvia’s highly successful HyFlyer I and II ATI projects which delivered breakthrough first flights of hydrogen-electric aircraft and were transformative in establishing greater confidence in the potential for commercial, zero-emission flights this decade.  

During HyFlyer II, ZeroAvia also demonstrated the largest HTPEM stack module for aviation, showing technology readiness for scaling fuel cells into large commercial aircraft. AFCAD will further develop this technology to unlock the market for large regional turboprops, regional jets and, ultimately, narrowbody aircraft, as well as developing the supporting UK supply chain and advancing the pathway for manufacturing. 

ZeroAvia sees HTPEM fuel cell power generation as key to developing zero-emission propulsion systems for aircraft larger than 20-seats, and the technology is integral to the company’s ZA2000 2-5.4 MW engine for 40-80 seat planes.