ToffeeX is proud to announce our participation in Project HyFan, an innovative study funded by a £550K grant from Innovate UK. The study aims to advance hydrogen fuel cell propulsion systems for the commercial drone market. Greenjets will lead the project and bring together a consortium that includes Bramble Energy, Aurata Technologies, and ToffeeX.
Over the course of this 18-month program, Project HyFan will focus on developing and de-risking key technologies for an integrated hydrogen fuel cell propulsion system. This will culminate in a series of ground and flight tests. The findings will pave the way for this critical technology’s commercialization and further development.
Tackling challenges in fuel cell systems
The current generation of fuel cell (FC) systems for drones presents two main challenges. First, they occupy a large portion of the aircraft’s payload volume, which limits drones’ commercial potential by reducing useful payload capacity. Second, fuel cell systems require significant repair, maintenance, and overhaul downtime, slowing operational efficiency.
Project HyFan aims to resolve these issues by closely integrating the fuel cell stack, balance of plant, heat exchangers, and propulsion system. By freeing up payload volume (targeting an increase of 20-30L) and reducing downtime by a factor of 6, the project hopes to unlock new levels of efficiency and performance for commercial drones.
ToffeeX’s role in HyFan
ToffeeX will leverage its AI-enhanced generative design software to optimize the heat exchangers within the propulsion system. ToffeeX’s software will help create compact, lightweight, and highly efficient thermal management solutions that support the integrated fuel cell system by automating and streamlining the design process.
Marco Pietropaoli, CEO of ToffeeX, commented:
It is great to be involved in this project to advance the use of fuel cells in the aircraft industry. It is a perfect scenario to demonstrate how the engineering approach must evolve with technology and how the use of innovative generative design software such as ToffeeX can help solve complex design challenges.
At ToffeeX, we recognize hydrogen as one of the most promising alternatives for powering zero-emission aircraft. When produced from renewable energy sources, hydrogen generates no carbon dioxide, with water as its primary by-product, making it a crucial component in the journey towards sustainable aviation
Hyfan consortium partners
- Greenjets: Greenjets is spearheading the development of quiet, efficient electric propulsion systems and will lead the overall integration of the fuel cell propulsor and propulsion system.
- Bramble Energy: Bringing their unique PCBFC™ technology, Bramble Energy will focus on designing the hydrogen fuel cell stack for drones.
- Aurata Technologies: Specializing in thermal system integration, Aurata will tackle the thermal challenges within the system architecture, ensuring seamless integration and optimized performance.
James Baxter, Technical Director at Aurata, said:
We are delighted to be part of this innovative consortium pushing the boundaries of fuel cell propulsion. As specialists in thermal systems, the tools developed in HyFan will allow Aurata to support our customers by increasing the speed and quality of systems architecture and component specification for fuel cell systems in novel applications.
Dr. Guido Monterzino, CTO at Greenjets, said:
Our customers want quiet, efficient and long-range propulsion systems. With this project, we will develop a one-of-a-kind fuel cell propulsor that will also increase their payload volume and reduce their maintenance downtime.
Dr Vidal Bharath, CCO at Bramble said:
Bramble’s innovative PCBFC™ fuel cell technology and its completely customisable nature means we can deliver a design alongside our consortium partners that will address the current issues including payload, making fuel cells a viable solution for commercial drones.
A growing market and future impact
With the commercial drone market growing at over 20% CAGR, the potential market for this integrated fuel-cell propulsion system is substantial. The consortium has already secured four early adopter customers to help guide the project’s development and ensure market readiness. Beyond the drone sector, the project will contribute to the growth of the UK’s hydrogen technology supply chain, generating new jobs and positioning the UK as a leader in sustainable aviation technologies.
The success of Project HyFan will help drive innovation in hydrogen propulsion and further the development of next-generation aerospace technologies.
About Greenjets:
Greenjets is leading the charge in advanced air mobility, developing quiet, efficient, and cost-effective electric engines for drones, air taxis, and regional aircraft. Learn more at Greenjets.
About Bramble Energy:
Bramble Energy is revolutionizing hydrogen fuel cells with their PCBFC™ technology, providing scalable, low-cost solutions for a Net Zero world. Learn more at Bramble Energy.
About Aurata Technologies:
Aurata Technologies specializes in solving complex multi-system challenges through thermal simulation and systems integration, particularly in the hydrogen fuel cell and battery sectors. Learn more at Aurata Technologies.
About Innovate UK
Innovate UK is the UK’s national innovation agency, supporting businesses in developing and scaling breakthrough ideas. Part of UK Research and Innovation (UKRI), it funds cutting-edge projects across various industries, driving economic growth and boosting competitiveness in the global market.