Edge Autonomy is a developer of innovative power technology for unmanned aircraft systems (UAS), enhancing versatility for mission critical operations.
Mission demands evolve constantly, shifting not just over months or years, but within days or hours. The more adaptable a UAS is, the better it can respond to these changing needs.
A reliable UAS solution must support long-range and extended-duration missions while remaining silent, lightweight, and portable—key factors in ensuring operational readiness and mission success.
Addressing the Need for Adaptability
As the logistical footprint of airborne intelligence, surveillance, and reconnaissance (ISR) operations decreases, the scope of mission requirements continues to expand. Small uncrewed aircraft systems (sUAS) and Group 2 UAS are now tasked with missions traditionally reserved for larger aircraft.
This shift demands that these aircraft not only become smaller and lighter but also offer the flexibility to address a wide variety of mission scenarios. These could include operations in extreme cold, nighttime or low-light conditions, the integration of multiple payloads, and targeting distant objectives. A capable sUAS must deliver operational and logistical versatility to meet such challenges.
Josh Stinson, Edge Autonomy Chief Growth Officer and Army Special Forces Veteran, commented, “A more robust common operating picture is vital to mission success. To achieve greater awareness of the operational environment, today’s warfighter needs to see farther and understand more. The mission flexibility of an uncrewed system and its ability to provide greater dwell time in that environment directly impacts the effectiveness of the warfighter.”
How Power Sources Influence UAS Endurance
Silent propulsion systems have become an essential feature for sUAS platforms, as most ISR missions require the aircraft to remain undetected. Traditional internal-combustion engines make this infeasible, driving most sUAS platforms toward electric propulsion powered by high-energy batteries.
While effective for stealth, battery-only systems face significant limitations, particularly in range, endurance, and payload capacity compared to traditional propulsion systems.
Imagine a power system capable of quadrupling endurance, range, and payload capacity while maintaining silent operations.
Such a system, compatible with an sUAS’s existing battery slot, would offer unmatched flexibility, including hot-swapping capabilities between flights to match mission requirements. Edge Autonomy’s advanced micro-tubular solid-oxide fuel cell (MT-SOFC) delivers exactly that.
The MT-SOFC Solution
Edge Autonomy’s MT-SOFC, a TRL 9 flight-proven technology, uses propane as fuel rather than the hydrogen required by conventional fuel cells. With its advanced onboard filtration system, this fuel cell can efficiently process even low-grade propane.
This means operators can source propane from military kitchens, local barbecue stands, or remote gas stations, ensuring availability anywhere on the planet.
Propane is ubiquitous, found in every city and village worldwide, and the MT-SOFC’s compatibility with this widely accessible fuel eliminates the need for specialized logistics.
Advancing Beyond Battery Reliance
With nearly four decades of aeronautical innovation, Edge Autonomy has consistently aligned its advancements with evolving battlefield requirements.
While maintaining leadership in long-endurance and long-range reconnaissance capabilities, its uncrewed aircraft systems adapt seamlessly to diverse ISR mission needs.
As the original equipment manufacturer (OEM) of the VXE30 Stalker UAS and its advanced Havoc configuration, Edge Autonomy has equipped these platforms with state-of-the-art batteries capable of six-hour electric-only flight durations.
For missions demanding extended range or endurance, the MT-SOFC provides an alternative, field-swappable power source that extends flight parameters up to four times. Remarkably, this fuel cell retains all-electric functionality, ensuring silent operations throughout the mission.
After 25 years of rigorous testing across global operational environments, the propane-powered MT-SOFC has consistently demonstrated its effectiveness in extreme conditions. With hundreds of thousands of flight hours logged on six continents, this technology enhances the endurance and operational flexibility of battery-powered UAS platforms.
Dual Power Source Versatility
The VXE30 Stalker enhances mission adaptability by allowing operators to choose between battery and fuel cell power for each flight. For shorter missions requiring 4-6 hours of flight time, a battery suffices.
For extended missions requiring greater range and endurance, operators can opt for the fuel cell. The MT-SOFC serves not as a replacement but as an additional tool to significantly enhance performance when needed.
Ensuring Mission Success with Versatile Refueling
In ISR missions, every second and every gram of payload weight is critical. Dr. Tom Westrich, VP of Technology at Edge Autonomy, stated, “Imagine a drone operator flying a long-range mission in a remote environment. The combination of a battery and fuel cell – like we see in the VXE30 Stalker – extends the flight, but if refueling means the need to carry specialized fuel then the mission is ultimately made less efficient.
“But a soldier can locate propane in almost any environment, and because of our unique filtration system, it doesn’t matter how dirty that propane is—the UAV operator can simply fill a tank from ANY source and use that to directly power the VXE30 Stalker. They’ll be flying again in minutes.”
By incorporating a compact and efficient fuel filtration system, Edge Autonomy’s aircraft can operate using propane sourced from virtually any location. Whether sourced from a gas station, convenience store, or village kitchen, readily available propane keeps mission operations seamless and uninterrupted.
How Does Edge Autonomy’s Fuel Cell Filtration System Work?
Edge Autonomy’s unique filtration system removes sulfur and other additives commonly found in propane, which could otherwise hinder the electrochemical reactions essential for power generation. This process ensures clean and reliable fuel for optimal operational performance.
In contrast, hydrogen-based fuel cells require complex logistical support for producing metal hydrides—a process impractical for field operations. The simplicity and efficiency of the MT-SOFC makes it ideal for real-world deployment.
Swapping out the two external fuel tanks and filters on the VXE30’s advanced Havoc configuration is quick and straightforward, thanks to their placement on the aircraft’s wings. This design ensures ease of access and minimal downtime.
Westrich explained, “To hot swap a single tank on a fuel cell for the VXE30 Stalker, you need about 20 seconds—at most 60 seconds if you’re taking your time.”
Innovations Driving Mission Performance
The long-term benefits of a dual-power UAS are substantial. Extended flight times, increased range, and enhanced field efficiency make the VXE30 Stalker a standout in ISR operations. Its ability to seamlessly switch between power sources and use readily available fuel underscores its operational superiority and adaptability.
Stinson added, “Longer flight times and more range increase overall mission efficiency, as well as the likelihood of success. Buying the operator the time and flexibility needed to accurately assess each situation provides the opportunity to respond to the most immediate needs of the battlespace.
“Every piece of equipment and pound of weight makes a difference to the warfighter. When you don’t have to account for additional batteries or specialized fuel with your supplies you have room for other essentials like food, water, and ammunition.
“We consider our customers’ missions to be our missions as well, and we are constantly innovating toward greater success and efficiency for them. I’ve been there myself, as have many of our researchers and engineers, and we appreciate the technology that goes into battlefield operations.”
