The SuperStack Flex system reportedly delivers over 1.2kW/kg specific power, a sustained 150kW output, and 175kW peak output.

The defence customer may deploy the system in unmanned aerial vehicles, with potential applications extending to small aircraft, maritime, and ground systems.

Notably, ZeroAvia highlighted that the fuel cell has passed airworthiness testing and is ready to be used in actual aircraft trials.

In the final stages of system testing, the SuperStack provided power back to ZeroAvia’s Propulsion Centre of Excellence in Everett, Washington.

The aviation tech firm said it generated enough power to offset the entire building’s consumption.

Additionally, ZeroAvia used 3D printing to cut balance-of-plant components by about 50%, reducing the system’s weight and volume by the same margin.

“Fewer parts mean lighter, more compact, more reliable, and less costly systems,” the firm’s statement explained.

Val Miftakhov, Founder and CEO, stressed that fuel cell systems must evolve to enable electric flight.

“With lower noise and heat signatures, lower maintenance costs, increased endurance and the ability to generate fuel locally, there are enormous capability benefits,” he said.

“We can generate an amazing amount of electrical power at a really low weight, opening up all kinds of possibilities for new vehicles in both the civil and defence arenas.”

While ZeroAvia continues to advance its hydrogen aviation technologies, the industry remains divided over hydrogen’s near-term decarbonisation potential.

For example, major players such as Airbus have delayed their hydrogen plans by more than five years.