ZeroAvia has completed a full flight profile ground test of its certification-intent low temperature proton exchange membrane (LTPEM) fuel cell power generation system for the ZA600 hydrogen-electric powertrain. The test simulated a 250 nautical mile flight in a Cessna Caravan 208B, equivalent to the journey between London Heathrow and Dublin Airport.

The system demonstrated consistent performance, with each 200kW module producing 170kW for take-off, 132kW during a 23-minute climb and 83kW for a 90-minute cruise. Four modules will provide power for the 600kW electric propulsion system, which has received G-1 and P-1 issue papers from the FAA.

ZeroAvia’s multi-stack balance-of-plant design offers 1.4kW/kg power density and fault tolerance through segregated power legs. Working with The Lee Company, the team developed a Venturi ejector device to recirculate hydrogen gas. This passive device avoids the bulk and power draw of an electric blower and simplifies qualification requirements.

The company has built a 2MW-capable test lab at its Gloucestershire R&D centre to accelerate validation. Founder and CEO Val Miftakhov says: “We are now seeing the final design replicating customer needs in ground testing, and pushing the boundaries of performance with new innovations.”