New drop-in “AEROPAK” fuel cell system makes stealthy electric UAS fly longer & farther

AEROPAK, a next-generation fuel cell power system recently developedby Horizon Fuel Cell Technologies will increase the flight endurance of small and stealthy electricunmanned aerial systems (UAS) by as much as 300 percent. The fuel cell technologicaladvancements will bring significant enhancements to UAS, making them more effective in persistentintelligence, surveillance and reconnaissance (ISR) missions, a main focus area for leading defenseand security organizations around the world.

Starting evaluation shipments this summer, Horizon’s new AEROPAK brings an immediateperformance improvement over today’s best available battery systems. Designed for high-impact andable to operate at up to 22,000 feet (6500m), the complete system integrates Horizon’s record-settingfuel cell technology with new refillable dry-fuel cartridges. Storing 900Wh of usable electricalenergy and weighing just 4.4 lbs (2kg), the AEROPAK provides up to four times the endurancecapability of advanced lithium batteries currently in use. The miniaturized power system makes itvery easy to use as drop-in replacement for battery packs currently in service, eliminating costly

airframe modifications.

According to G2 solutions, a Seattle-based market research firm specializing in Aerospace/Defense,“The use of pervasive UAS is increasing because the persistent ISR capabilities they bring areunmatched.”

Electric-powered UAS bring important capabilities - reduced acoustic signature, smaller size - andoffer real advantages - lower acquisition cost, fuel savings - to ISR operations. Where batteryperformance limits the effective use of these promising systems, the AEROPAK next-generationfuel cell power systems will improve versatility and open new mission possibilities for smallerelectric UAS.

In addition to increasing flight endurance, the new fuel cell system also makes it possible for smalltactical UAS to integrate more power-hungry electronic devices such as electro-optical sensors,infrared cameras and laser designators. The new fuel cell systems can also be used to power remoteground systems and recharging stations, or even serve as an auxiliary electric power supply forlarger systems.

Horizon’s AEROPAK is the first of a series of commercially available fuel cell systems that can becustomized to fit a variety of platforms and scaled up to provide as much as several kilowatts ofpower, making it suitable for all sizes and configurations of electric powered UAS.

Over the next 10 years, industry analysts expect the acquisition market for UAS to exceed $44billion in the U.S. alone. According to Ron Stearns of G2 solutions, “Fuel cells have the potential toimprove the Size, Weight and Power (SWaP) configuration for tactical UAS propulsion, leading toincreased UAS endurance or expanded sensor and/or communications-relay capabilities.”