Blueflite Has Developed a 3D-Printed Hydrogen Storage System for UAVs

In the years to come, drones could play a decisive role in many areas, ensuring the rapid and safe transport of goods. Isolated rural areas in particular stand to benefit, as drones can quickly supply them with medicines or emergency foodstuffs. In addition to their use for humanitarian purposes, drones also offer advantages for agriculture and mining. Many companies are therefore working to make unmanned aerial vehicles (UAVs) even more reliable, faster and more efficient.

Demand is growing, especially for long-distance flights, hence the increasing interest in fuels such as hydrogen to power UAVs. For this reason, Australian UAV logistics platform Blueflite has teamed up with the Australian Northern Territory Government and Charles Darwin University (CDU) to develop a hydrogen-based fuel storage technology for UAVs in a joint project. This project was also made possible by the use of additive manufacturing.

Making the part

The Position of Blueflite on the UAV Market

Already today, long-range drones account for almost a quarter of the global drone market, which is expected to reach $3 billion by 2033. According to Airservices Australia, the number of drone flights in 2024 has so far been 1.5 million (individual take-offs and landings), but flights are expected to reach around 60.4 million by 2043. These figures illustrate the need to develop high-performance UAVs and scalable solutions. By integrating hydrogen fuel cells, for example, it is possible to optimize their efficiency and increase their range by up to 700% compared with conventional lithium-ion batteries.

UAVs have the potential to shrink distances, increase services in remote areas and decarbonise last mile transportation. In conjunction with CDU, H3 Dynamics and support from the Northern Territory Government we will establish a composite hydrogen tank manufacturing capability that does not exist in Australia and integrate it into our proven UAV platform.- Frank Noppel, CEO of Blueflite

Blueflite has therefore launched a project to develop a scalable hydrogen fuel storage technology for UAVs. The hydrogen tanks are to be produced locally and then integrated into the UAVs. To achieve this, Blueflite enlisted the support of Charles Darwin University, which, thanks to its expertise in printing technologies, brought advanced production methods for drone manufacturing to the project. These include the placement of carbon fibers by an industrial robot, a technology known as Advanced Fiber Placement (AFP).

Part of the Blueflite team with the industrial robot

This is the only robot of its kind in Australia, enabling the manufacture of lightweight, high-pressure-resistant hydrogen tanks. CDU’s Energy Resource Institute is also involved in the project, carrying out tests on hydrogen production and filling of the manufactured tanks. At a later stage, Blueflite will integrate the hydrogen tanks into the UAVs.

Although the project is still in its early stages, the Uavs are considered safe and reliable. Blueflite will also open a new office in Darwin for the project and aims, in addition to developing high-performance hydrogen tanks, to increase sales and create new jobs. Over the next five years, the company anticipates additional revenues of around AUD 600,000 and the hiring of 17 new professionals.

“The long-term goal for Blueflite^® and our partners in Darwin is to coalesce a range of skills, knowledge and capability to position the NT as a leader in sustainable aviation and manufacturing, with ripple effects across various sectors, industries and the Top End economy,” concludes Franck Noppel. You can find out more about the project HERE.

Frank Noppel, the CEO of Blueflite

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*All Photo Credits: Blueflite