ZeroAvia is making its SuperStack Flex fuel cell technology available to companies developing various uncrewed aircraft systems and VTOL aircraft. This week, the propulsion innovator reported that new additive manufacturing techniques have allowed it to scale the hardware to provide smaller versions of the equipment with lower power levels of between 100 and 600 kilowatts.

Originally, the low-temperature proton exchange membrane fuel cell stacks were developed for the ZA600 hydrogen-electric propulsion system ZeroAvia is using to convert fixed-wing regional aircraft with up to 20 seats. The company said it is in discussions with an undisclosed customer over plans to apply a scaled modular version of the hardware for an unspecified application.

Improvements to the production process are based on use of selective laser sintering powder-bed additive manufacturing. This has allowed ZeroAvia’s engineering team to quickly design, build, and test different iterations of the SuperStack Flex concept.

In the process, the company has managed to reduce the number of parts from more than 200 to fewer than 100, cutting weight and volume in half. The SuperStack Flex consists of anode, cathode, and coolant manifolds, as well as thermal management, humidification, and air compression systems.

“We are creating step-change aerospace fuel cell systems at a fraction of the usual development time and cost,” said ZeroAvia founder and CEO Val Miftakhov. “SuperStack Flux can be customized to an aircraft OEM’s precise needs, power requirements, and aircraft layout, so we can get them flying on fuel cells quickly, and thus improve the flight duration, life cycle, and the total cost of ownership of the aircraft.”

Meanwhile, ZeroAvia now holds its FAA G-1 issue paper as it progresses through the type certification process for the ZA600 electric propulsion system (EPS). In February, Jetcruzer International ordered an EPS to be applied to the six-seat hybrid-electric 500E light aircraft it is developing. ZeroAvia has previously said it aims to have the powertrain ready to enter commercial service on converted regional airliners by the end of 2025.