Over recent years, fuel cell-based electric propulsion has become recognised globally as an exciting technology to deliver true zero-emission aircraft, in no small part thanks to the ATI’s Fly Zero concepts and the funding support for ZeroAvia’s two HyFlyer projects.
ZeroAvia flew the world’s first commercial-scale hydrogen-electric aircraft in September 2020. This formed part of thesuccessful HyFlyer Project, supported by the ATI, Innovate UK, and Department for Business and Trade.In December of the same year, it was announced that the ATI had awarded ZeroAvia, and consortium partners Aeristech and EMEC, £12.3m to undertake HyFlyer II, a project to further develop the first certifiable zero-emission engine for up to 20 seat aircraft.
The programme focused on developing a viable 600kW hydrogen-electric engine in advance of certification work, culminating in successful flight testing aboard a Dornier 228 19-seat aircraft. The project also sought to explore innovative alternative fuel cell technologies such as High Temperature PEM (HTPEM) fuel cells that could scale hydrogen-electric flight for larger aircraft, and to further develop the hydrogen production and fueling infrastructure to support increased testing demands.
Long-term ATI support, including the Fly Zero project and its recommendations for zero-carbon emission air travel, has been critical to ZeroAvia growing its footprint in the UK. The ATI has continued to support ZeroAvia in the development of the world’s first commercial-scale hydrogen-electric aircraft, across both the HyFlyer I and II projects, enabling it to successfully grow its footprint in the UK. The ATI’s thought leadership in this area: the Fly Zero project, has been critical to supporting the development of these aircraft.
ZeroAvia successfully flew the prototype ZA600 aboard the Dornier 228 testbed in January 2023, following 19 months of intensive activity to retrofit the left-hand engine with the zero-emission replacement and secure permit to fly with the CAA. Since that historic first flight, the company has flown the Dornier 228 ten times, increasing the test envelope to maximum speed (150 knots), altitude (5,000 feet), and duration (22 minutes), and demonstrating exceptional performance from the fuel cell systems.
Over the course of the programme, ZeroAvia has grown its UK workforce from below 40 to well over 200, as well as contributing to substantial job creation in the supply chain. The demonstration has been integral to ZeroAvia securing a $116m Series C investment with investors including Airbus and UK Infrastructure Bank, following the successful Series B raise in 2022 of in excess of $72 million. Most of the private VC investment spent has been in the UK, with the HyFlyer II project leading to investment significantly beyond what could have been foreseen at the start of the project.
The development of the ZA600 represents a multi-billion-dollar export market for the UK as ZeroAvia now works through certification with the CAA and FAA with a view to entry-into-service by the end of 2025. HyFlyer II has also enabled ZeroAvia to establish partnerships with key OEMs with relevant airframes in their portfolio in the shape of Textron and De Havilland of Canada. The project has enabled ZeroAvia to progress its technology for ZA600 from TRL3 to TRL5 and support the development of promising pathways for enhanced or larger aircraft capabilities, such as advancing HTPEM fuel cell tech for aviation from TRL 3 to 4.
The technology development begun in the HyFlyer programmes promises the removal of up to 1.3 GT of CO2e by 2040.
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Total project value:
£12.3m
Project partners:Aeristech ,
EMEC,
Airbus
From 40 to 200
UK employees
The world’s first
commercial-scale hydrogen-electric aircraft
1.3 GT of CO2e
potential savings by 2040
"The Aerospace Technology Institute’s continued support with the second HyFlyer project was critical for ZeroAvia in growing its footprint substantially in the UK, adding hundreds of jobs and attracting hundreds of millions in investment. The legacy of this project, however, could be in laying the foundations for the certification of the world’s first zero-emission engine for commercial aircraft, and catalysing a clean flight revolution."
Val MiftakhovCEO, ZeroAvia
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