Technology & Innovation
DLR Achieves Megawatt Milestone in Hydrogen Fuel Cell Aviation Tech
DLR’s BALIS facility operates hydrogen fuel cell systems above one megawatt, advancing scalable zero-emission aviation propulsion technology.
German Aerospace Center Achieves Historic Megawatt Milestone in Hydrogen Fuel Cell Aviation Technology
The German Aerospace Center (DLR) has reached a pivotal moment in Hydrogen aviation development by successfully operating fuel cell systems and electric motors at power outputs exceeding one megawatt each through their BALIS test infrastructure. This achievement marks a critical breakthrough in scaling hydrogen fuel cell technology for aviation, validating integrated propulsion systems at power levels necessary for commercial flight. The milestone comes as the global hydrogen aircraft market experiences rapid growth, positioning Germany at the forefront of zero-emission aviation innovation.
This technical success is underpinned by significant government investment and a unique, modular test facility capable of evaluating megawatt-class fuel cell systems for multiple transportation domains. The BALIS project, along with its follow-up BALIS 2.0 initiative, demonstrates sustained commitment to advancing hydrogen Propulsion technologies that could transform aviation, shipping, and heavy-duty vehicles. As the industry seeks sustainable solutions, the DLR’s achievement signals a new era for clean, high-power mobility.
Historical Foundation and Project Evolution
The BALIS project originated from Germany’s strategic focus on hydrogen-powered mobility as part of national climate goals. Launched in 2021 with support from the Federal Ministry of Transport and Digital Infrastructure, the initiative aimed to develop and test megawatt-class fuel cell propulsion systems for aviation and other sectors. The facility, located at the Empfingen Innovation Campus, was designed for modular, flexible testing, with 26 million euros in initial funding and subsequent expansions for infrastructure and research.
BALIS’s infrastructure was developed in collaboration with AVL and other partners, ensuring comprehensive capabilities for system and component validation. The project’s evolution continued with BALIS 2.0, a targeted initiative focused on developing a 350 kW fuel cell module as a scalable building block for larger systems. This follow-up, led by H2FLY and Diehl Aerospace, received 9.3 million euros in funding and reflects a shift towards aviation-specific applications and Certification requirements.
These efforts are embedded in Germany’s broader National Innovation Programme Hydrogen and Fuel Cell Technology, which coordinates funding and research across the hydrogen value chain. As DLR’s leadership notes, the step from ground-based validation to flight certification is complex and time-consuming, and large-scale testbeds like BALIS are essential for de-risking this transition.
Technical Achievement and Engineering Significance
The recent DLR milestone stands out for integrating and operating both fuel cell systems and electric motors above the one megawatt threshold, levels not yet available commercially. The BALIS team electrically coupled twelve fuel cell modules, each with over 400 individual cells, creating a sophisticated, modular system. This approach addresses the current market limitation, where the largest mobile fuel cells offer only several hundred kilowatts.
Project leader Cornelie Bänsch described the accomplishment as a major milestone in setting up and commissioning the facility’s first-generation fuel cell test system. The technical challenge extended beyond mere power scaling to achieving stable, coordinated operation across all modules. Advanced operating strategies were developed to manage this complexity, with plans to further increase output and run dynamic load profiles that simulate real-world aviation conditions.
The BALIS system’s capacity extends to 1.5 megawatts, suitable for applications in ships, heavy-duty vehicles, and aviation. Its modular design allows for detailed investigations of individual components as well as complete powertrain systems, including refueling infrastructure and control technology. This level of integration provides crucial validation for the aviation industry’s shift toward hydrogen-powered flight.
“This is an important milestone in the set-up and commissioning of the test facility and the first generation of the fuel cell test system. Systems of this power class are not yet available on the market, the technical challenge lies in developing and integrating all the components so that they operate stably at high outputs of one megawatt or more.”
, Cornelie Bänsch, DLR Institute of Engineering Thermodynamics
Infrastructure Architecture and Testing Capabilities
The BALIS test facility is unique worldwide for its ability to develop and test megawatt-class fuel cell propulsion systems. Located at the E2U Empfingen Development Centre, its modular container-based architecture enables flexible, scalable evaluation of both individual components and integrated powertrains. Researchers can simulate various load cases and operational scenarios, mirroring actual aircraft mission requirements from ground operations to cruise flight.
Core facility components include fuel cell systems, liquid hydrogen tanks, high-performance electric motors, batteries, and advanced control and regulation technology. DLR is also building a test tank and refueling infrastructure for liquid hydrogen, addressing the critical challenge of high-density storage required in aviation. This infrastructure supports realistic operational testing, such as simulating taxi, takeoff, climb, and cruise with sustained high power output.
The facility’s comprehensive capabilities make it a preferred location for collaboration with aeronautics institutes and industry partners. Its ability to accommodate full-scale system integration and dynamic testing bridges the gap between laboratory research and commercial aviation applications, accelerating technology development and de-risking future deployment.
Economic Context and Market Dynamics
The hydrogen aviation sector is experiencing rapid expansion, with the global hydrogen aircraft market valued at $826 million in 2023 and projected to reach $4.8 billion by 2034. The broader aircraft fuel cells market is expected to grow from $2.82 billion in 2025 to $24.63 billion by 2035. This growth is driven by increased adoption of sustainable aviation fuels, regulatory pressure to reduce emissions, and substantial public and private investment.
Government funding has been instrumental in enabling BALIS achievements, with 29 million euros allocated to the original facility and 9.3 million euros for BALIS 2.0. These investments are part of coordinated national and European strategies to support hydrogen research and infrastructure. Private sector engagement is also increasing, as major aerospace firms and Startups invest in hydrogen-powered aircraft development.
Cost competitiveness remains a key challenge. Green hydrogen production costs are currently higher than conventional fuels, but government incentives and economies of scale are expected to narrow this gap. The development of supply chains, refueling infrastructure, and certification standards will be critical for commercial viability and widespread adoption.
Aviation Applications and Commercial Potential
The demonstration of megawatt-class fuel cell systems unlocks significant potential for hydrogen-powered aviation, especially for regional aircraft with 40 to 80 passengers and ranges up to 1,000 kilometers. The BALIS systems’ scalability and modularity enable applications across different aircraft types, from small commuter planes to larger commercial jets as technology matures.
Certification and integration present technical hurdles, with aviation requiring the highest safety standards (Design Assurance Level A). BALIS 2.0 is addressing these through component development, system design, and verification testing. Initial ground tests of the 350 kW module are planned for 2025, forming the basis for future flight certification and operational deployment.
International competition is intensifying, with Airbus’s ZEROe project and American, Asian, and UK initiatives all targeting hydrogen aviation. Regulatory frameworks, such as the FAA’s Hydrogen-Fueled Aircraft Safety and Certification Roadmap and the UK CAA’s Hydrogen Sandbox Challenge, are evolving to support certification and market introduction, though commercial deployment is expected in the second half of the 2030s.
“Federal funding for BALIS 2.0 demonstrates the growing significance of hydrogen fuel cell systems as a viable solution for clean aviation. The project insights will propel the development of megawatt-class powertrains, significantly accelerating the transition to sustainable, zero-emission flight.”
, Professor Josef Kallo, H2FLY
Safety, Environmental Impact, and Regulatory Framework
Safety is paramount in hydrogen aviation, with comprehensive protocols for handling, storage, and system integration. The BALIS facility incorporates multiple safety barriers, monitoring systems, and modular isolation to minimize risk during testing. Aviation-specific standards require extensive validation and redundancy, with regulatory authorities developing new frameworks for hydrogen certification.
Environmentally, hydrogen fuel cell aviation offers the promise of zero-carbon flight, especially when using green hydrogen produced from renewables. The aviation sector currently accounts for 2-3% of global CO2 emissions, and hydrogen-powered regional aircraft could deliver meaningful reductions. Life-cycle benefits depend on the hydrogen source, and infrastructure impacts must be considered in sustainability assessments.
Regulatory harmonization is underway, with the FAA, EASA, and UK CAA collaborating on standards, certification, and safety research. The development of international standards and certification pathways is essential for global market adoption, with ground-based validation and special conditions paving the way for future commercial operations.
Conclusion
The DLR’s achievement of operating megawatt-class fuel cell systems marks a watershed moment in the evolution of hydrogen aviation technology. The BALIS test facility’s unique capabilities have validated the feasibility of scaling hydrogen propulsion to commercial aviation power levels, providing a foundation for zero-emission flight and cross-sector applications in shipping and heavy vehicles.
As the market, regulatory, and technological landscapes evolve, Germany’s leadership through BALIS positions it at the forefront of sustainable aviation innovation. The path to commercial deployment will require sustained investment, international collaboration, and continued technical progress, but the groundwork laid by BALIS offers a compelling blueprint for the future of clean, high-power transportation.
FAQ
What is the BALIS project?
BALIS is a test infrastructure developed by the German Aerospace Center (DLR) to develop and validate megawatt-class hydrogen fuel cell propulsion systems for aviation and other transportation sectors.
Why is the megawatt threshold significant?
Exceeding one megawatt in integrated fuel cell and electric motor operation demonstrates the scalability of hydrogen technology for commercial aviation, where high power outputs are essential for practical application.
When will hydrogen-powered aircraft be commercially available?
While ground testing and system validation are underway, commercial deployment is expected in the second half of the 2030s, pending further technical development and regulatory certification.
What are the main challenges for hydrogen aviation?
Key challenges include achieving power density suitable for flight, developing safe and efficient hydrogen storage, integrating complex systems, and meeting stringent certification standards.
How is the environmental impact addressed?
Hydrogen fuel cell aviation can offer zero-emission flight, especially when using green hydrogen. The environmental benefits depend on the hydrogen production method and the development of supporting infrastructure.
Sources:
DLR: BALIS test system components cross megawatt threshold for the first time
Photo Credit: DLR
Technology & Innovation
Electra EL2 Lands at Manhattan Heliport in eSTOL First
Electra’s EL2 hybrid-electric demonstrator operated from a Manhattan heliport on Oct. 26, 2026, validating its urban eSTOL concept.
Electra successfully operated its fixed-wing hybrid-electric demonstrator aircraft from a Manhattan heliport on October 26, 2026, marking the first time a non-vertical takeoff aircraft has utilized the downtown infrastructure.
The flight of the EL2 Ultra Short demonstrator at the Downtown Skyport (JRB) validates the manufacturer’s “Direct Aviation” concept, which aims to operate electric short takeoff and landing (eSTOL) aircraft from existing urban spaces like heliports and barges. The operation was conducted in partnership with Skyports Infrastructure and detailed in a company press release.
Demonstrating urban eSTOL capabilities
The EL2 demonstrator accessed a 62-foot-by-62-foot landing pad situated on a 300-foot barge at the Lower Manhattan facility. Electra’s aircraft utilize blown-lift technology and distributed electric propulsion to achieve takeoff and landing distances as short as 150 feet, eliminating the need for traditional airport runways.
In a press release, Electra Chief Executive Officer Marc Allen described the operation as a historic milestone for downtown Manhattan.
“This same capability will fundamentally transform how people travel in our nation by making it faster and easier to get them to their destinations,” Allen said. “What’s even more interesting is that we didn’t need to build a new runway to do it. We worked with partners who see new possibilities in existing infrastructure.”
Skyports Infrastructure General Manager for US Heliports & Vertiports Robbie Ladov noted that the flight demonstrates how emerging aircraft technologies can unlock new uses for existing aviation infrastructure.
Electra projects that its eSTOL operations could yield substantial time savings for regional travel along the United States East Coast. The company estimates potential savings of three hours and 45 minutes for trips between New York City and Boston, three hours and 30 minutes between New York City and Washington, D.C., and 45 minutes for flights to Philadelphia.
The EL9 production path and manufacturing footprint
The EL2 serves as a two-seat technology demonstrator for Electra’s planned commercial production aircraft, the EL9. The EL9 is designed to carry nine passengers or 3,000 pounds of cargo over distances up to 330 nautical miles, with a maximum ferry range of 1,100 nautical miles.
Power for the EL9 will be supplied by a combination of battery packs and a Safran TG600 turbogenerator capable of producing 600 kilowatts of electricity. Electra and Safran Helicopter Engines finalized a life-of-program production agreement for the turbogenerator in July 2026.
Manufacturing preparations are advancing alongside the flight test program. In September 2026, Electra signed an agreement with Atlas to manufacture and assemble EL9 airframes, with initial deliveries expected in 2027. This follows a July 2026 announcement of an $850 million investment to construct a manufacturing facility in Springfield, Ohio, designed to produce up to 800 aircraft annually.
Electra targets 2027 for the first flight testing of the EL9, with commercial service entry planned for 2030. The company has secured over 2,200 provisional orders from more than 60 commercial operators, including Bristow Group, which holds the first five delivery slots. The manufacturer is backed by strategic investors including Lockheed Martin Ventures, Honeywell Aerospace, Safran, and Prysm Capital, and holds contracts with the U.S. Air Force, U.S. Army, U.S. Navy, and NASA.
Positioning eSTOL against vertical lift
Electra is positioning its eSTOL design as a distinct alternative to the electric vertical takeoff and landing (eVTOL) aircraft currently dominating the advanced air mobility sector. The company states that the EL9 offers 2.5 times the payload and 10 times the range of comparable Helicopters and eVTOLs, alongside a 70 percent reduction in operating costs.
The Manhattan demonstration is part of a broader “Life Beyond Runways” campaign. On October 19, 2026, Electra announced the selection of five sites in Norway to host hybrid-electric aircraft demonstrations in 2027, expanding its operational testing to international markets.
AirPro News analysis
We view the Manhattan heliport demonstration as a critical proof of concept for the eSTOL market segment. By proving that a fixed-wing aircraft can operate from a 300-foot barge in a dense urban environment, Electra challenges the prevailing industry assumption that urban air mobility strictly requires vertical lift capabilities.
Bypassing the high energy demands and complex aerodynamic transitions of vertical flight allows Electra to prioritize payload and range while still accessing constrained infrastructure. Crucially, the fixed-wing design offers a lower-risk certification pathway under existing Federal Aviation Administration (FAA) Part 23 regulations, avoiding the regulatory uncertainties currently facing powered-lift eVTOL developers. If the 150-foot performance translates reliably to the nine-passenger EL9, the addressable market for regional “Direct Aviation” could be substantial, particularly for operators looking to avoid congested major airport hubs.
Photo Credit: Electra
Technology & Innovation
Skyfly Technologies Raises $10M to Certify Axe eVTOL
Skyfly Technologies closes $10M seed round to certify its Axe eVTOL under FAA MOSAIC rules, targeting 2027 customer deliveries.
British aerospace developer Skyfly Technologies has closed a $10 million seed funding round to transition its two-seat Axe electric vertical takeoff and landing (eVTOL) aircraft from prototype to certified production. The investment will also accelerate the development of a hybrid-electric unmanned variant aimed at the defense sector.
The funding round, announced in an October 20, 2026 press release, is backed by HICO Investment Group and Archangel Ventures. The capital injection is designed to leverage the United States Federal Aviation Administration (FAA) Modernization of Special Airworthiness Certification (MOSAIC) rules, which established a new regulatory pathway for private eVTOL ownership.
Capitalizing on MOSAIC regulations
The eVTOL industry has predominantly focused on commercial air taxi operations, a sector requiring extensive capital and complex regulatory approvals. Skyfly has opted for a different market segment by targeting private ownership. This strategy relies heavily on the FAA MOSAIC reforms, which came into force in July 2026.
The MOSAIC rules rewrote the Light Sport Aircraft category to include electric propulsion, multi-motor designs, and vertical take-off capabilities. This regulatory shift created a direct certification pathway for personal eVTOLs like the Axe.
“This investment gives us the resources to take the Axe from a flying prototype to a certified aircraft in customers’ hands. The FAA’s MOSAIC rules have opened a route to market that simply did not exist for electric aircraft before, and the Axe was designed for exactly this category. HICO and Archangel understood that timing, and their backing lets us move at the pace the opportunity demands: completing certification and standing up series production.”
The statement was provided by Michael Thompson, CEO of Skyfly Technologies, in the company’s funding announcement.
Axe eVTOL specifications and testing progress
The Axe is a two-seat electric aircraft designed to minimize mechanical complexity. It utilizes eight fixed-angle electric motors for vertical lift and fixed wings for forward flight, eliminating the need for tilting motors or rotary wings. According to company specifications, the aircraft features a cruising speed of 100 mph, a range of 100 miles, and a payload capacity of 200 kg (440 pounds). Total flight time is estimated between 60 and 90 minutes.
Skyfly has completed over 100 piloted prototype flights since the pre-production model first flew in March 2025. The testing program included Europe‘s first airfield-to-airfield eVTOL flight. The company established a dedicated flight test team in the United States in 2025 and showcased the aircraft at EAA AirVenture Oshkosh in both 2025 and 2026. The Axe currently holds experimental flight permits in both the UK and the US.
Chris Hartnoll, Managing Director of HICO Investment Group, noted the efficiency of the development program. He stated that the engineering team had successfully designed and built a new aircraft from scratch and is now navigating a brand-new certification pathway.
Dual-use technology and the Longbow variant
The inclusion of Archangel Ventures, a defense-focused fund, highlights the dual-use potential of Skyfly’s technology. Alongside the passenger-carrying Axe, the company is developing the Longbow, a hybrid-electric unmanned variant tailored for government and military applications.
Skyfly unveiled its first hybrid propulsion system in July 2026. The Longbow variant is projected to offer an extended range of over 347 nautical miles, addressing military requirements for runway-independent cargo resupply and surveillance operations.
Nicholas Nelson, General Partner at Archangel Ventures, stated that the Longbow addresses a clear requirement for unmanned systems capable of moving meaningful payloads over significant distances without relying on traditional runway infrastructure.
Skyfly’s path to production
Founded in 2019 and headquartered in Thorpe Mandeville, UK, Skyfly Technologies is led by Chief Technology Officer Dr. William Brooks. Brooks brings over three decades of experience in light aircraft development and has certified more than 2,000 aircraft currently in service.
With the $10 million seed funding secured, Skyfly is scaling its operations and production capabilities across the UK and the US. The company currently has 61 private customers on its order book for the Axe eVTOL and is targeting 2027 for its first customer deliveries.
AirPro News analysis
We view Skyfly’s strategy as a pragmatic departure from the broader eVTOL industry consensus. By targeting the FAA MOSAIC Light Sport Aircraft category rather than pursuing commercial Part 135 air taxi certification, the company bypasses the billion-dollar capital requirements that have constrained its competitors. The MOSAIC rules provide a defined, achievable regulatory target for a privately owned, multi-motor electric aircraft.
Additionally, the development of the Longbow variant provides a critical hedge. The consumer eVTOL market remains unproven, but military demand for runway-independent, medium-payload logistics drones is immediate and well-funded. Securing backing from a defense-focused investor like Archangel Ventures suggests Skyfly is positioning itself to generate near-term defense revenue while the private ownership market matures.
Photo Credit: Skyfly Technologies
Technology & Innovation
Signature Aviation and UrbanV Launch US AAM Joint Venture
Signature Aviation and UrbanV launch SUVA, a joint venture to build a nationwide eVTOL infrastructure network across the US.
Signature Aviation and Italian vertiport operator UrbanV have formally launched a joint venture to develop and operate a nationwide Advanced Air Mobility (AAM) infrastructure network across the United States.
Announced on October 21, 2026, during the NBAA-BACE convention, the Signature UrbanV Alliance (SUVA) aims to transition electric vertical takeoff and landing (eVTOL) operations from isolated test sites to a scalable, agnostic network. According to a press release issued by Signature Aviation, the partnership will initially integrate electric aircraft operations into the company’s existing terminal footprint before expanding to purpose-built facilities.
Transitioning from test sites to scalable networks
The SUVA joint venture, first proposed in an initial agreement on June 12, 2025, is designed to provide an agnostic infrastructure platform. Rather than catering to a single aircraft manufacturer, the network will support multiple eVTOL and electric conventional takeoff and landing (eCTOL) operators.
The alliance plans a phased rollout. Initial operations will focus on integrating charging systems, aircraft handling, and passenger services into existing Signature Aviation facilities. As commercial demand scales, SUVA intends to construct dedicated, purpose-built vertiports in urban and regional destinations to create a connected on-airport and off-airport network.
“Advanced Air Mobility will not be enabled by individual sites alone. It will require connected infrastructure that is ready ahead of large-scale commercial operations and links airports with the places people want to reach. SUVA enables us to turn that vision into a scalable network, combining existing aviation assets with dedicated vertiports as the market develops.”
The statement was provided by Massimiliano Pane, Executive Director of UrbanV.
Leveraging existing aviation real estate
The joint venture combines UrbanV’s dedicated vertiport development experience with Signature Aviation’s extensive fixed-base operator (FBO) footprint. Signature operates the world’s largest network of Private jets terminals, with over 200 locations globally. The multinational aviation services company, headquartered in Orlando, Florida, was taken private in June 2021 following a $4.7 billion acquisition by a consortium that included Blackstone, Global Infrastructure Partners, and Cascade Investment.
UrbanV, headquartered in Rome, Italy, was established by European airport operators Aeroporti di Roma, SAVE Group, Aeroporto di Bologna, and Aéroports de la Côte d’Azur. The company currently operates the UV-0 test vertiport at Rome Fiumicino Airport (FCO), which hosted Italy’s first crewed eVTOL public test flight in October 2022.
Derek DeCross, Chief Commercial Officer at Signature Aviation, noted that the alliance allows the company to shape both the physical infrastructure and the passenger experience for the AAM sector.
“Through the Signature UrbanV Alliance, we have an opportunity to help shape not only the infrastructure behind Advanced Air Mobility, but the guest experience itself, leveraging our network, operational expertise and commitment to hospitality to create a more connected, convenient and elevated journey for travelers.”
Regulatory alignment and market context
The formal launch of SUVA aligns with advancing regulatory frameworks for AAM infrastructure in the United States. On October 22, 2026, the Federal Aviation Administration (FAA) released updated draft design standards for vertical lift infrastructure. The FAA documentation addresses core layout requirements, lighting, charging systems, and the integration of vertiports at existing airports.
SUVA will collaborate with airports, municipalities, real estate owners, and regulatory bodies to establish the technical and commercial frameworks required for widespread electric aircraft deployment.
AirPro News analysis
The Advanced Air Mobility sector has long faced a structural challenge regarding the simultaneous development of certified aircraft and the infrastructure required to operate them. By utilizing Signature Aviation’s existing real estate portfolio, SUVA bypasses the immediate need for complex greenfield vertiport construction in dense urban areas. This strategy offers a pragmatic bridge to early commercial eVTOL operations. The timing of the launch also positions the joint venture to directly apply the FAA’s newly updated draft design standards, ensuring that initial retrofits at existing FBOs align with the agency’s evolving regulatory expectations.
Photo Credit: Signature Aviation
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