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ZeroAvia launches electric and hydrogen aviation components offering; manufacturing plans

ZeroAvia will be offering some of its key components designed for its hydrogen-electric engines to other clean aviation innovators. The move allows ZeroAvia to build upon the multi-billion dollar per annum market for its hydrogen-electric powertrain family, maximizing the company’s investment in R&D and its strategy of vertical integration.

With the certification work for the ZA600 engine for up to 20-seat aircraft underway, and the underpinning technology for the ZA2000 engine for up to 90-seat aircraft in advanced development, ZeroAvia has conducted component market research and sees significant opportunity in the following areas:

  • Advanced electric motors for aviation, including a 660 kW max-power direct-drive motor capable of speeds up to 2,200 rpm, and the HyperCore 900kW modular motor capable of speeds up to 20,000 rpm.

  • Silicon carbide inverters. The 200kW continuous power bidirectional inverter design offers a power density above 20 kW/kg and is available in single (225kW peak / 200kW continuous) and dual (450kW peak / 400kW continuous) configurations. The inverters are designed and produced following aerospace standards, allowing a high-power density and reduced weight with advanced thermal management technologies and integration to enable reliable high performance for high altitude and engine compartment location.

  • Low temperature Proton Exchange Membrane (LT-PEM) fuel cell configurations (in partnership with PowerCell). ZeroAvia’s SuperStack Flex architecture is a customizable 100-400kW fuel cell power generation platform designed to meet a range of different aerospace power, performance, and packaging requirements, while maintaining exceptional pressure, mass flow rate, humidity, and temperature control.

  • High temperature PEM (HT-PEM) fuel cell stacks and full power generation systems. ZeroAvia’s High-Temperature Proton Exchange Membrane (HTPEM) fuel cell stack is a turbo-air cooled modular system which offers up to 3.5 kW/kg specific power, supporting a variety of traditional aviation and VTOL applications.

  • Aviation fuel cell compressor is a leading-edge compressor capable of supporting up to 900kW fuel cell applications up to 15,000 feet. The compressor is designed specifically for fuel cell applications and designed for aerospace standards from the start.

The company is in active discussions on potential deals with a number of companies working on electric and hydrogen aviation innovations.

To facilitate the production of the electric propulsion systems (specifically, power electronics and electric motors) for both its own powertrains and its component offering, ZeroAvia opened its propulsion center of excellence at Paine Field in Everett, north of Seattle.

ZeroAvia also plans a separate facility focused on producing hydrogen fuel cell systems—a Hydrogen Center of Excellence—and is currently exploring site selection.



There is an excellent video here where access has been given to Zero Avia's lab to see the process of building and testing their HT fuel cell module. They are aiming for 10,000 hours of durability but don't say how near they are to that!

The challenges of developing it sound 'interesting!' ;-)

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