TECHNICAL POINT OF CONTACT (TPOC)
Adam Jolley
Michael Allen
PROJECTED CMMC LEVEL REQUIREMENT
Level 2 (Self)
TECHNOLOGY AREAS
None
MODERNIZATION PRIORITIES
Renewable Energy Generation and Storage
KEYWORDS
Fuel cell; Electrical power; Energy storage; Hydrogen; Electrochemical; Unmanned Aircraft System; UAS
OBJECTIVE
Develop a rugged, reliable, efficient fuel cell system with a high power-to-weight ratio and incorporated intelligent control algorithms and feature modularity.
DESCRIPTION
The Navy and Marine Corps are actively seeking to enhance the range, endurance, and payload capacity of their unmanned aircraft systems (UAS). In recent years, hydrogen fuel cells have emerged as a promising technology for propulsion and power systems that can improve UAS operational capabilities [Refs 1-4].
While various fuel cell types exist, proton exchange membrane (PEM) fuel cells are most prominently used for UAS applications [Refs 5-6]. However, further improvements to performance and reliability are necessary before widespread adoption into the services. This STTR topic seeks to explore any fuel cell solution that can meet the key performance, reliability, and design metrics required for integration into military UAS.
The Navy is seeking a modular fuel cell system where the stack and balance-of-plant can be adjusted to meet a range of electrical power outputs from an initial 1kW to 20kW, with the potential to exceed 100kW.
Proposals should address the following key system parameters:
Full system power-to-weight ratio of 500 W/kg, including the thermal management system.
Overall efficiency of 50% or greater (versus the fuel's lower heating value) when operating at half of the maximum power output.
Rugged and reliable, capable of achieving over 200 full on/off cycles and a lifetime of 1,000+ hours with minimal maintenance.
Startup and shutdown time of less than 10 minutes.
Capable of operation up to 15,000 feet altitude.
Safe and hardened for military UAS applications.
Capable of starting and operating at both full power and idle in MIL-STD-810H basic hot and basic cold environments.
Adherence to shock and vibration requirements [Ref 7].
An advanced monitoring and control system to autonomously optimize control parameters, maximize system performance, and provide health monitoring and diagnostics.
Additional Considerations:
While gaseous hydrogen is the expected fuel, solutions using other fuels will be considered, especially if they offer logistical benefits.
Preference will be given to systems with minimal thermal and audible signatures.
Additional consideration will be given to solutions that can withstand the high g-force requirements of tube-launched systems.
PHASE I
Develop a concept for a comprehensive design for a fuel cell system that meets the key performance parameters previously outlined. Substantiate the design concept with sufficient data, such as CAD drawings, i-V polarization curves, and/or results from modeling and simulation, to demonstrate the system's capabilities.
Demonstrate modularity by addressing two distinct power configurations: a 1 kW system with a total weight of 5 lbs, and a 10 kW system with a total weight of 40 lbs.
Clearly define the control schemes and algorithms for monitoring and autonomously controlling the fuel cell for both system configurations.
Ensure that the design demonstrates compatibility with UAS integration. (Note: To aid in this effort, the Government will provide essential UAS requirement specifications, including integration interfaces, dimensions, electrical connectors, voltage requirements, and communication protocols (e.g., CAN bus, serial).)
Provide prototype plans to be developed under Phase II.
PHASE II
Develop, fabricate, and demonstrate a fuel cell system prototype based on the design established in Phase I.
Conduct bench testing of the completed system using a UAS power profile provided by the Government to demonstrate operational performance and to demonstrate the system's initial environmental, reliability, and lifetime capabilities.
Implement and test the advanced control system to demonstrate that it optimizes the fuel cell's performance while providing diagnostics and prognostics on system health.
Collaborate with a UAS manufacturer selected by the Government to integrate and demonstrate the fuel cell system.
PHASE III DUAL USE APPLICATIONS
Transition the fuel cell system to a fully integrated and manufacturable product by developing a robust manufacturing process; demonstrating Low-Rate Initial Production (LRIP) capability to deliver the fuel cell systems at scale; continuing collaboration with a UAS manufacturer to deliver a fully integrated product that provides improved operational capability; and demonstrating the performance of the integrated UAS in various operational exercises and scenarios.
The fuel cell technology developed in this topic offers significant benefits for the private sector. Commercial UAS vendors exploring fuel cell systems to improve platform endurance could adopt this technology as a drop-in replacement. Furthermore, existing applications that currently use fuel cells, such as forklifts and stationary or mobile backup power systems, could leverage the reliability and lifetime improvements demonstrated in this effort.
REFERENCES
Frantzman, Seth. Heven Drones unveils new hydrogen-powered, long range UAV at IDEX. Defense Business Report, February 13, 2025.
https://breakingdefense.com/2025/02/heven-drones-unveils-new-hydrogen-powered-long-range-uav-at-idex/
BlueBird Revolutionizes Tactical VTOL UAVs with Hydrogen Fuel-Dell Technology. Fuel Cell Works, February 18, 2025. https://fuelcellsworks.com/2025/02/18/fuel-cells/bluebird-revolutionizes-tactical-vtol-uavs-with-hydrogen-fuel-cell-technology
Hamisevicz, Mary. NRL Demonstrates Hydrogen Technology Solutions for Marine Corps. U.S. Naval Research Laboratory Corporate Communications, July 6, 2023. https://www.nrl.navy.mil/Media/News/Article/3603318/nrl-demonstrates-hydrogen-technology-solutions-for-marine-corps/
Joby Demonstrates Potential for Emissions-free Regional Journeys with Landmark 523-mile Hydrogen-electric Flight. Joby Aviation, PR, July 10, 2024. https://www.jobyaviation.com/news/joby-demonstrates-potential-regional-journeys-landmark-hydrogen-electric-flight/
Types of Fuel Cells. U.S. Department of Energy. https://www.energy.gov/eere/fuelcells/types-fuel-cells
Boukoberine, Mohamed Nadir; Zhou, Zhibin and Benbouzid, Mohamed. A critical review on unmanned aerial vehicles power supply and energy management: Solutions, strategies, and prospects. Applied Energy, Volume 255, 1 December 2019, 113823. https://www.sciencedirect.com/science/article/abs/pii/S0306261919315107
MIL-STD-810H ENVIRONMENTAL ENGINEERING CONSIDERATIONS AND LABORATORY TESTS. U.S. Department of Defense, 31 January 2019. https://cvgstrategy.com/wp-content/uploads/2019/03/MIL-STD-810H.pdf
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