The ScanEagle platform has logged more than 800,000 flight hours in military and civilian applications, making it one of the most successful UAV platforms to date. In addition to propulsion power, ScanEagle requires 60W of onboard power for its payload

Fuel cell-powered systems offer compelling value for unmanned aerial vehicles due to improved reliability over small internal combustion engines, as well as very low heat and noise signatures. We believe that fuel cell systems have an extraordinary opportunity to play a key role in the propulsion of many unmanned systems. Our work with Insitu on the ScanEagle is an excellent example of the potential for fuel cells.

—Paul Osenar, President of Protonex

Insitu’s ScanEagle is a versatile platform with multiple payload capabilities, including providing high-definition imaging at a fraction of the cost of larger UAV systems. The ScanEagle is operated in conjunction with Insitu’s Mark4 Launcher—a low-maintenance, runway-independent platform—along with its SkyHook recovery system.

In May 2015, Insitu selected Orbital Corporation as their preferred engine supplier for the ScanEagle UAV. Orbital’s new UAV engine and propulsion system includes an advanced Orbital fuel and oil supply module. The module allows all engine-related systems, including the fuel and oil supply systems, to be shipped from Orbital to Insitu in one assembled unit.

In August 2015, Insitu issued an initial batch order contract to Orbital valued at US$9.7 million for UAV engines.

ScanEagle is 1.55 meters (5.1 feet) in length, has a wingspan of 3.11 meters (10.2 feet) and maximum takeoff weight of 22 kilograms (48.5 lbs). The ScanEagle can fly at a maximum speed of 41.2 meters per second (80 knots), reach a ceiling of 5,944 meters (19,500 feet) and has an endurance capability of more than 24-hours.

Use of the Protonex fuel cell propulsion modules are expected to provide a number of advantages over traditional internal combustion engine propulsion systems, including: significant improvement in the expected MTBF (mean time between failures) of up to 5x; silent operation; 100% throttle flexibility, including mid-air start-stop capability; and use of existing JP8 fuel in ground refueling systems.

Work related to the integration of the Protonex fuel cell propulsion module into the ScanEagle system is ongoing, with flight demonstrations planned for the second half of 2016.