As aviation moves toward greener solutions, Aurora Flight Sciences is at the forefront of battery and fuel cell innovation.
Explore how their advanced energy lab is enhancing energy storage, extending flight endurance, and shaping the future of sustainable aerospace technology.
Pushing the Boundaries of Battery Innovation
Aviation demands energy solutions that are not only powerful but also lightweight and reliable. Aurora’s energy lab specializes in designing custom lithium-ion battery packs that optimize energy density while maintaining minimal weight. These advancements are particularly crucial for autonomous electric vertical takeoff and landing (eVTOL) aircraft, such as the SKIRON-X small unmanned aircraft system (sUAS), where battery efficiency directly impacts flight endurance and operational capabilities.
SKIRON-X from Aurora Flight Sciences.
Among Aurora’s latest developments is a prototype pouch-cell battery that delivers up to 22% more energy with only a slight weight increase compared to traditional cylindrical cells. Enhanced with a sophisticated battery management system (BMS), these batteries monitor voltage, temperature, and degradation in real time, improving safety and performance predictions. Engineers have also created an auxiliary belly-mounted battery for the SKIRON-X, incorporating next-generation materials to push endurance even further. Recent tests have demonstrated remarkable success, with SKIRON-X achieving an impressive 5-hour 24-minute flight on battery power alone.
Expanding Flight Endurance with Hydrogen Fuel Cells
Aurora isn’t stopping at battery-powered advancements—hydrogen fuel cell technology is also a key focus. In August, the company’s hydrogen-powered SKIRON-XLE successfully completed a seven-hour flight, setting a new benchmark for endurance in Group 2 unmanned systems. Hydrogen fuel cells offer a compelling alternative for long-duration missions, combining high energy efficiency with reduced environmental impact.
Rigorous Testing for Real-World Performance
Ensuring the reliability of these energy solutions is paramount. Aurora’s energy lab is equipped with advanced thermal chambers, high-voltage test systems, and ultra-high precision coulometry (UHPC) systems that allow engineers to simulate real-world flight conditions. These testing protocols help refine energy storage solutions by comparing real-world performance data to manufacturer specifications, ensuring accuracy and reliability in critical applications. The lab also conducts rigorous safety and certification tests, meeting the highest industry standards for operational use.
