Flight endurance enhancement via lightweight composite PEM fuel cell stack for Mini-UAVs: Modelling, manufacturing and testing
International Journal of Hydrogen Energy, vol.201, 2026 (SCI-Expanded, Scopus)
- Publication Type: Article / Article
- Volume: 201
- Publication Date: 2026
- Doi Number: 10.1016/j.ijhydene.2025.152930
- Journal Name: International Journal of Hydrogen Energy
- Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Artic & Antarctic Regions, Chemical Abstracts Core, Chimica, Compendex, Environment Index, INSPEC
- Keywords: Flight endurance, Gravimetric power density, Hybrid power system, Lightweight stack, Mini-UAV, PEM fuel cell
- Ankara Yıldırım Beyazıt University Affiliated: Yes
Abstract
Proton Exchange Membrane (PEM) fuel cells offer a promising alternative to conventional battery and internal combustion systems in mini-unmanned aerial vehicles (mini-UAVs) due to their high energy density and zero emissions. However, the integration of fuel cell systems into compact aerial platforms necessitates careful optimization of weight and thermal management. In this study, a lightweight composite-stack PEM fuel cell system was designed, manufactured, and tested to evaluate its impact on flight endurance. Bipolar plates were fabricated from composite graphite, and metallic components were gold-coated stainless steel with minimized thickness. The complete 32-cell stack, including fans and endplates, weighed only 641 g while delivering a nominal power of 295 W at 20,06V and peak power of 320 W at 18.36 V, corresponding to a gravimetric power density of 499 W/kg for peak power. The stack was integrated into a mini-UAV to drive the motor, and thrust performance was tested. Ground tests and climatic chamber experiments at −20 °C demonstrated reliable performance and environmental robustness. Compared to a traditional LiPo battery setup, the hybrid system offers a projected flight time extension from 4.5 up to 8 h under cruise conditions. These findings demonstrate that weight-optimized PEM fuel cell systems can significantly enhance the operational range of mini-UAVs and pave the way toward fully fuel-cell-powered aerial missions.