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Orbital UAV

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Innovative Heavy Fuel Engines for UAVs Australia
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Orbital UAV

Innovative Heavy Fuel Engines for UAVs

4 Whipple St, Balcatta, WA 6021, AUSTRALIA Australia Regional Offices
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Orbital UAV is a world-leading developer of integrated heavy fuel engine systems for military and commercial drones. With a focus on Group 2 and 3 tactical UAS (unmanned aerial system) platforms, we provide innovative propulsion systems that enable global defense forces to field the state of the art in unmanned ISR (intelligence, surveillance and reconnaissance) and battlefield logistics.

With 40 years of experience in developing advanced engine solutions, and 15 years of experience as the global leader in spark-ignited heavy fuel propulsion technology, we supply and work closely with the world’s largest developers of tactical UAVs, including Insitu and Textron.

aerosonde uav engine

FlexDI

Spark ignition technology for heavy fuel UAV engines

Our spark-ignited heavy fuel engines are based around our proprietary FlexDI technology, featuring a spray-guided direct fuel injection system that utilizes injected air to atomize the fuel. The extremely fine level of atomization results in increased surface area and improves vaporization.

FlexDI - spark ignition technology for UAVs

We have also developed an aerospace-qualified intelligent electronic propulsion management system that provides a range of built-in UAV-specific functionality including anti-stall, power management, speed control and engine protection.

Our engines are designed to provide highly efficient and reliable combustion of a range of heavy fuels including JP5, JP-8 and Jet-A1, allowing them to satisfy single-fuel policies that are currently being enacted by many defense forces around the world today. All Orbital heavy fuel engines are also able to run on gasoline, making them highly versatile.

Our Engines

50cc Heavy Fuel Engine

Orbital 50cc Heavy Fuel UAV EngineThe Orbital 50cc Heavy Fuel Engine utilizes an air-cooled two-stroke single-cylinder design, and is capable of delivering 3.7 hp (2.8 kW) at 6500 RPM. Weighing just 3 kg, it can provide 250W of electrical power.

The real-world capabilities of the 50cc HFE have been rigorously proven, with over 150,000 service hours in the field with Insitu. This engine is the propulsion system of choice for the Insitu ScanEagle 3, a long-endurance tactical ISR drone in service with the U.S. and Australian armed forces.

For more information on the 50cc Heavy Fuel UAV Engine, please contact us.

75cc Heavy Fuel Engine

Orbital 75cc Heavy Fuel UAV EngineThe Orbital 75cc Heavy Fuel Engine utilizes an air-cooled two-stroke single-cylinder design, and is capable of delivering 5.2 hp (3.9 kW) at 6500 RPM. Weighing just 4.4 kg, it can provide customizable levels of electrical power from 300 to 500W, to suit customer-specific requirements.

The 75cc HFE was selected for the Aerosonde MK4.7, a tactical hybrid VTOL sUAS designed for land-based and maritime ISR. It has undergone over 650,000 hours of in-field service with Textron.

For more information on the 75cc Heavy Fuel UAV Engine, please contact us.

150cc Heavy Fuel Engine

Orbital 150cc Heavy Fuel UAV EngineThe Orbital 150cc Heavy Fuel Engine is our latest engine to enter full production, and features a horizontally-opposed twin-cylinder two-stroke boxer design. Weighing 6.4 kg, the MIL-STD-810H qualified engine can deliver 11.5 hp (8.5 kW) at 6500 RPM with customizable levels of electrical power from 300 to 1000W.

This engine has completed over 5000 hours of ground testing, as well as multiple 3x 150-hour FAR33.49b durability tests and 500-hour mission profile durability tests. It has been selected for Textron Systems’ Aerosonde MK4.8, a tactical hybrid VTOL UAS that has been purpose-built to meet the U.S. Army’s Future Vertical Lift requirements. It is also being provided to a leading Singaporean defense company.

For more information on the 150cc Heavy Fuel UAV Engine, please contact us.

Facilities & Services

Orbital UAV’s dual operations in Perth, Western Australia, and Oregon, USA, provide world-class facilities with capabilities in design, embedded electronic control, manufacturing and development, as well as testing of engines, fuels and oils, and engine management systems.

Orbital UAV Test Cell - Engine Prop Stand

Metrology

HALT HASS

Key test, development and production capabilities include:

  • Multiple engine test cells at each facility
  • In-house machine shop
  • Altitude simulation chamber with capability to 20,000ft; with temperature control to -35oC to 65oC
  • Semi-anechoic NVH room for noise assessments
  • Environment Stress Screening including HALT and HASS with simultaneous temperature and vibration
  • Comprehensive metrology department
  • Annual throughput capacity of 600+ new-build or MRO units at Australian facility & 240+ at US facility

Products

50cc Heavy Fuel Engine

3.7 hp two-stroke single-cylinder engine for tactical UAVs

75cc Heavy Fuel Engine

5.2 hp two-stroke single-cylinder engine for tactical UAVs

150cc Heavy Fuel Engine

11.5 hp two-stroke twin-cylinder engine for tactical UAVs

FlexECU

Advanced engine management systems for UAVs

Articles

Latest
Orbital UAV Unveils Advanced Power Management System for Heavy Fuel Engines

Orbital UAV has launched its new Power Management System (PMS), delivering advanced electrical control, protection, and remote start capabilities for heavy fuel drone engines

May 14, 2025
Upgraded UAS Engine Prototypes Delivered for Evaluation

New engine prototypes for Textron Systems’ Aerosonde® UAS have been delivered by Orbital UAV

Jun 21, 2023
Exploring Potential Propulsion System Concepts for New Heavy-Lift UAS

Orbital UAV will play a crucial role in the strategic deployment of Animal Dynamics' Stork-STM UAS, bringing a potential global operating domain to a vehicle designed to work in harsh, austere environments

Dec 12, 2022
Engine Shipments Commence for Tactical UAS

Orbital UAV has begun the first engine shipments to Insitu Pacific for the Australian Army’s next-generation Integrator uncrewed aerial system

Nov 04, 2022
Heavy Fuel Engine to be Tested on Tactical UAV

US defense company AeroVironment Inc. has acquired the latest heavy fuel engine by Orbital UAV for testing on its JUMP® 20 tactical UAV

Sep 20, 2022
Orbital UAV Engine Development Program Progresses to Second Stage

The Design & Development and Verification & Validation contract will see Orbital UAV conduct further engineering work and deliver three additional prototype engine systems during financial year 2023

Jul 28, 2022
New Collaboration Supports Next Generation of Unmanned Military Technology 

Orbital UAV and Anduril Asia Pacific will work on concepts, products and technical solutions in the uncrewed domain

May 11, 2022
Orbital UAV Supports US Navy Unmanned Cargo Transportation

Orbital UAV has entered into an agreement to provide unmanned cargo transport specialist Skyways with a heavy fuel engine that...

Nov 01, 2021
Orbital UAV Awarded Australian Defense Funding for Expansion

Orbital UAV has been awarded funding via the Australian government’s Defence Global Competitiveness Grant to support the company’s growing capabilities...

Sep 09, 2021
Orbital UAV Engine Delivered to Singapore Defense Company

Orbital UAV has confirmed the delivery of the first UAV (unmanned aerial vehicle) engine system to one of Singapore’s largest...

Jun 02, 2021
Orbital UAV Hosts Australian Minister for Defence Industry

Orbital Corporation has hosted Australia’s Minister for Defence Industry, the Hon Melissa Price MP, and Mr Vince Connelly MP, Federal...

May 20, 2021
Prototype Engine for Aerosonde UAS Program Delivered

Orbital UAV has achieved the first major milestone in its engine development program for the Textron Aerosonde UAV (unmanned aerial...

May 14, 2021
Orbital UAV Signs Engine Development Agreement for Aerosonde

The new agreement includes a 12-month engine development program, which will enable the integration of an Orbital UAV-designed core engine,...

Mar 30, 2021
Australian Minister for Defence Tours Orbital UAV

Orbital UAV has hosted Australian Minister for Defence, Senator the Hon Linda Reynolds CSC, at its headquarters in Balcatta, Perth....

Jul 19, 2020
Orbital UAV to Develop Hybrid Propulsion System

Orbital UAV has been selected by Northrop Grumman Corporation to develop a hybrid propulsion system for a Vertical Take-Off and...

Apr 23, 2020
Orbital UAV to Supply Engines to Singaporean Defense Firm

Orbital UAV has signed a Memorandum of Understanding (MoU) for the design, development and initial low-rate production of UAV (unmanned...

Mar 26, 2020
Insitu Selects Orbital UAV as Primary Engine Supplier

Orbital UAV has announced that it has signed a Memorandum of Understanding (MoU) with UAS (unmanned aerial system) manufacturer Insitu...

Mar 15, 2020
Orbital Provides Second UAV Engine Model to Insitu

Orbital UAV has announced that, as specified in the company’s Long Term Agreement (LTA) with Insitu Inc., it has begun...

Jan 16, 2020
Modular Propulsion System Completes First Test Flights

Orbital UAV has announced that it has performed the first flight tests in Australia of its propulsion systems for unmanned...

Oct 31, 2019
Orbital UAV Receives Official Government Visit

Orbital Corporation has announced that The Honourable Kim Beazley AC, Governor of Western Australia, recently visited its Perth headquarters, as...

May 15, 2019
Orbital UAV Hosts Australian Office of Defence West

Orbital UAV has announced that it has hosted a delegation from the Office of Defence West – the Western Australian...

Feb 20, 2019
Orbital UAV Developing Modular Propulsion Solutions

Orbital Corporation has announced that the company is developing a range of modular propulsion solutions for unmanned aerial vehicles (UAVs)....

Oct 15, 2018
Orbital UAV Opens Operational Facility in USA

Orbital Corporation Ltd has announced the official opening of its purpose-built operational facility in Hood River, Oregon, USA. This milestone...

Sep 28, 2018
Orbital Signs Agreement with Insitu for UAV Propulsion Systems

Orbital Corporation has announced that it has signed a long-term agreement (LTA) with Insitu, valued at up to US$91m (A$120...

Dec 23, 2016
Orbital Receives Second Insitu Propulsion System Order

Orbital Corporation Limited has received a further batch order for propulsion systems from Insitu Inc., a subsidiary of The Boeing...

Aug 31, 2016
Orbital Delivers First Batch of UAV Engines to Insitu

Orbital Corporation Limited, a developer of fuel and engine technologies, has announced that it has delivered the first shipment of...

May 09, 2016
Orbital Receives Insitu Order for UAV Engines and Propulsion Systems

Orbital Corporation Limited (“Orbital” or “the Company”) has received an order valued at US$9.7 million (A$12 million) from Insitu Inc....

Aug 28, 2015
Orbital to Supply Engine and Propulsion System for Insitu’s New ScanEagle UAV

Orbital Corporation Limited (“Orbital”) is pleased to announce that Insitu Inc. (“Insitu”), a subsidiary of The Boeing Company (“Boeing”), have...

May 05, 2015
Orbital’s ScanEagle Propulsion System Passes FAA Engine Endurance Test

Orbital, a manufacturer of engines and fuel/control systems, has announced that its ScanEagle propulsion system, designed and developed for Insitu,...

Feb 13, 2015
Orbital Delivers First ScanEagle UAV Engine to Insitu

Orbital Corporation Limited (Orbital) has delivered the first purpose-built ScanEagle Unmanned Aerial Vehicle (UAV) propulsion system to Insitu Inc, a...

Sep 16, 2014
Regional Offices & Locations
Orbital Corporation Limited Australia 4 Whipple St, Balcatta, WA 6021, AUSTRALIA +61 (8) 9441 2311 Contact Website
Orbital UAV USA, LLC United States of America 210 Wasco Loop, Hood River, OR 97031 USA +1 541 716 5930 Website
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