Blueflite leverages AM to produce hydrogen fuel cells for UAVs
Thanks to Charles Darwin University’s Automated Carbon Fiber Placement (AFP) capabilities
Blueflite, a drone-based logistics platform for faster and more cost-effective deliveries, has developed a safe and reliable storage technique for hydrogen fuels for unmanned aerial vehicles (UAVs) through a collaborative early-stage project supported by Australia’s Northern Territory (NT) Government. The project, which will also see Blueflite open its Darwin-based premises, seeks to develop a lightweight, high-pressure, hydrogen vessel (tank) using Advanced Fiber Placement (AFP) technology.
The collaboration will see Blueflite leverage Charles Darwin University’s (CDU) additive manufacturing capabilities, including the use of an industrial robot with advanced Automated Carbon Fiber Placement (AFP) capabilities. The AFP robot at CDU is the only one of its kind in Australia and offers a significant improvement over traditional methods of composite vessel manufacture.
Long-range UAVs play a crucial role in numerous sectors, including medical, agricultural, services, and mining industries – particularly in geographically isolated or vast regions. In the medical field, they facilitate quick and efficient transport of medical supplies, vaccines, and even emergency medical services to remote areas. In agriculture, UAVs can transform crop monitoring, precision agriculture, and pest control.
According to a recent Airservices Australia report, the number of drone flights (single take-off and landing) will increase to approximately 60.4 million by 2043 – compared to 1.5 million in 2024. This increase is driven primarily by drones being used for goods deliveries. The global drone market – of which long-range drones represent almost a quarter of – is expected to grow to $3 billion USD by 2033. With increasing demands for long-range flights driving interest in new forms of fuel such as hydrogen, Blueflite plans to offer a scalable solution for all manner of UAV applications. The integration of hydrogen fuel cell technology into UAVs has the potential to enhance the range and efficiency of craft, as running on hydrogen rather than lithium-ion batteries is expected to increase range by 700%.
“UAVs have the potential to shrink distances, increase services in remote areas, and decarbonize 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,” said Frank Noppel, Chief Executive Officer of Blueflite. “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.”
Working alongside CDU’s Energy Resource Institute, the project will conduct trials for remote site hydrogen generation and filling of the locally manufactured hydrogen storage vessels. These tanks will be integrated into Blueflite’s UAVs, and flight trials will be conducted at the Darwin UAV Flight Test Range.
“The Northern Territory is ideally positioned to assist Blueflite® and its collaborators to succeed, not only do we have the right geographical conditions, but we also have the right support mechanisms and innovation ecosystem. Projects like this really lift our manufacturing industries eyes beyond the horizon and demonstrate our role in the transition to renewable energy,” said Charmaine Phillips, Northern Territory Director, of the Advanced Manufacturing Growth Centre.
The project is expected to deliver $600,000 AUD in additional revenue within five years and create at least seventeen new skilled roles at Blueflite’s new Darwin facility. Blueflite’s project is the tenth business to receive co-investment through the AMEF, which was launched in 2021.
