[Everett, WA & Kemble, UK: 11th March 2025] — ZeroAvia has announced a major advancement in hydrogen-electric propulsion with its SuperStack Flex fuel cell architecture, achieving over 1.0kW/kg specific net power at a full system level. Successfully demonstrated in a 150kW net power configuration for a key customer, this breakthrough enhances UAV and VTOL applications while unlocking new possibilities across the aerospace sector.

Revolutionary Manufacturing for Lighter, More Efficient Systems

ZeroAvia’s success stems from the innovative use of selective laser sintering (SLS) powder-bed additive manufacturing, allowing rapid design, testing, and production cycles. By consolidating the key balance-of-plant components—including the Anode, Cathode, Coolant Manifolds, thermal management, and air compression systems—the company has cut the number of parts by more than half, reducing weight and volume by approximately 50%.

Fewer parts mean improved efficiency, lower costs, and enhanced reliability—critical factors for aviation applications.

Scalable and Adaptable Power for Next-Generation Aircraft

The SuperStack Flex is a modular fuel cell platform capable of delivering between 100kW and 600kW of net continuous power. Optimised for UAVs, it also has applications in marine and ground vehicles. Its adaptable design allows for the separation of core systems, ensuring efficient integration into diverse airframes and overcoming space constraints.

Accelerating Industry Adoption

By prioritising certification with regulatory bodies like the CAA and FAA, ZeroAvia is facilitating the adoption of hydrogen fuel cell technology across multiple sectors. The company’s approach allows aircraft manufacturers to integrate SuperStack Flex seamlessly, accelerating R&D and enabling longer flight durations with lower operational costs.

A Leap Forward in Fuel Cell Innovation

Val Miftakhov, Founder & CEO of ZeroAvia, emphasised the significance of this achievement:

“Our team has really knocked it out of the park and delivered some truly world-leading engineering here. We are creating step-change aerospace fuel cell systems at a fraction of the usual development time and cost. SuperStack Flex can be customised to an aircraft OEM’s precise needs, power requirements, and layout, getting them flying on fuel cells quickly and improving flight duration, lifecycle, and total cost of ownership.”

With this milestone, ZeroAvia continues to push the boundaries of hydrogen-electric propulsion, positioning itself as a leader in the transition to cleaner, more efficient aviation.