The University of Sheffield AMRC is part of a new groundbreaking £17 million programme to fast-track the development of a new zero-emission hydrogen fuel cell system that could be powering commercial aircraft within the decade.

Project HEIGHTS is a three-year programme that aims to develop Intelligent Energy’s current 300kW modular aviation fuel cell platform, IE-FLIGHT™ 300, for next-generation aircraft. The AMRC has secured £1.3 million in funding from the Aerospace Technology Institute (ATI) as part of this wider initiative. 

The project consortium steered by Intelligent Energy, a leading UK hydrogen fuel cell manufacturer, is a collaboration involving the AMRC, Qdot Technology, the Manufacturing Technology Centre and several supply chain businesses.

The AMRC, part of the High Value Manufacturing (HVM) Catapult network, will provide its extensive expertise in hydrogen propulsion, advanced design and simulation, and high-performance electrical machines to support mass reduction and optimising manufacturing processes for Intelligent Energy's novel evaporatively cooled fuel cell system.

Initial applications of the technology include Electric Vertical Take-off and Landing (eVTOL) aircraft and short-range commuter planes. The new fuel cell system is expected to enter early service in Part 23 aircraft (with up to 19 seats) by the end of the decade, with scale-up plans targeting larger (Part 25) regional aircraft from the mid-2030s.

James Hunt, future propulsion lead for the AMRC, said: "When Intelligent Energy approached the AMRC about project HEIGHTS, we saw a pivotal opportunity to leverage the investments we've made in cutting-edge technology specifically aimed to address the challenges to decarbonising transportation."

The AMRC’s contributions will focus on critical areas, utilising its state-of-the-art facilities and expertise:

• Hydrogen Electric Propulsion Systems (HEPS) testbed at AMRC Cymru: The capability will be crucial for optimising the fuel cell stack assembly processes, ensuring efficiency and scalability.
• Design and manufacturing of a high-speed electric motor: Building upon the foundations established through the EPSRC-funded Future Electrical Machines Manufacturing (FEMM) hub, the AMRC will develop a high-speed electric motor for the compressor, a vital component in the fuel cell system.
• Design and simulation: The AMRC will help optimise the design and manufacture of some of the key sub-system elements of the fuel cell system, ensuring maximum efficiency and performance.

Project HEIGHTS addresses a key challenge in traditional fuel cell systems – how to keep the fuel cells at the correct operating temperature without introducing significant drag in cooling systems. In aviation particularly, minimising the heat exchanger size is critical to reduce mass and drag, and to optimise overall efficiency. 

IE’s patented direct water-injection technology uses air-cooled condensers with a 20–30 per cent smaller frontal area than rival liquid glycol radiators. Project HEIGHTS will develop this novel cooling method further to achieve an additional 30–40 per cent cut in heat exchanger size with support from partners. 

Hunt added: "This transformative work is happening right here in the UK, fostering new, high-value supply chains and creating skilled jobs. It is absolutely crucial for the UK to solidify its leadership in hydrogen fuel cell-powered flight, and projects like HEIGHTS are central to achieving that ambition. 

“This collaboration is not just technical; it's about actively pioneering the pathway to zero CO2 emission flight in commercial aviation."

David Woolhouse, Intelligent Energy CEO, said: “This is about getting hydrogen-powered aircraft in the air, and into service at scale, as quickly as possible. We firmly believe that hydrogen will be the primary energy source for flight, initially for smaller aircraft but eventually in the longer term for everything that flies.

“At Intelligent Energy, we have the IP built on 24 years’ experience to give us confidence we can be the technical leader in this sector. This project supports us making our modular system even smaller, lighter and more scalable.”

The investment comes as aviation faces rising pressure to cut emissions. Batteries remain constrained by weight and range, while hydrogen-electric propulsion is gaining traction as a cleaner, scalable alternative.

Jacqueline Castle, chief technology officer at the Aerospace Technology Institute (ATI) said: “Hydrogen as a fuel source is an essential part of the ATI’s technology roadmaps for future power and propulsion systems. We are delighted to be supporting Intelligent Energy’s HEIGHTS programme, which builds upon its prior expertise in fuel cell development to encompass novel means of addressing thermal management challenges associated with aircraft integration,

“The ATI’s FlyZero project identified the need for high-temperature fuel cell systems and world-class expertise on thermal management within the UK. This project brings the two together to develop what we expect to be a compelling, power dense solution for zero-carbon flight.”