IE-SOAR 800W hydrogen fuel cell power module for VTOL and fixed-wing UAVs

The IE-SOAR 800W is a hydrogen fuel cell power module for VTOL and fixed-wing UAVs from Intelligent Energy. This fuel cell for drones runs on hydrogen and ambient air to produce clean DC power, and it is designed to replace a battery directly so that the aircraft stays in the air longer and beyond-visual-line-of-sight (BVLOS) missions become practical. The architecture is modular, with a separate fuel cell and control box for flexible integration into the fuselage, and it is based on the architecture of the maker's proven higher-power product.

The module targets endurance-limited missions. Listed applications are parcel delivery, linear inspection, cinematography, civil inspection, agriculture, military surveillance, and LiDAR and mapping. Refueling takes minutes rather than the hours a battery needs to recharge. The datasheet gives example integrations with TPED/DOT certified, specialist and custom hydrogen cylinders, and flight time grows with cylinder volume, so the cylinder can be chosen to match the mission and the system mass budget.

The module delivers 0.8 kW of maximum continuous power. A peak power of 7.5 kW is quoted, but this figure depends on the hybrid battery used, so integrators should size the battery to the peak demand of the aircraft. The output is DC-DC regulated and configurable between 24 and 48 V. Two systems can be combined in parallel for double the output. The fuel cell power module has a mass of 1.45 kg, covering the fuel cell and the control box, while the hydrogen regulator is a separate item. Fuel cell and control box dimensions are listed in the specifications.

For integration, the unit is compatible with 6S to 12S battery architectures and follows load demand automatically, like a battery. Communication with the UAV or accessories runs over UART or CAN, and an SD card provides internal data storage for firmware updates, performance data and diagnostics. Hydrogen is supplied from a compressed-gas cylinder through a regulator rated for a maximum cylinder pressure of 350 bar. Range extender and battery management versions are available.

The system is designed for safety and reliability, with single point failure tolerance and built-in power system redundancy. Safety features are a dual redundant power system and a backup battery. The product is certified CE and FCC. Operating temperature is –5 to 40 °C, and the maximum altitude is 3,000 m, a range the datasheet notes may be widened depending on customer power requirements. A commercial warranty applies to the system.

Compared with an internal combustion engine, the fuel cell offers zero-emission, near silent and vibration-free operation, which suits payloads that need a stable platform and low noise signature. Compared with batteries, it offers increased flight time, fast refueling and built-in power system redundancy. Typical users are integrators of VTOL and fixed-wing UAVs in civil and military roles who need more endurance from a compact, battery-compatible power source.