Aviation of tomorrow

The aviation of tomorrow

Efforts to create alternatives for emissions-free air travel have been underway for some time. One of the most successful projects to date has been implemented by a focus project from ETH Zurich, known as CELLSIUS.

The vision of Cellsiusis to operate aircraft in a climate-neutral, efficient, and sustainable manner in the future. In the current project, this goal will be achieved using a hydrogen-powered fuel cell. The project team consists of dedicated students who can demonstrate their practical skills in engineering projects during their final year of bachelor studies. CELLSIUS is self-financed and is being realized in close collaboration with industry partners.

Swagelok Switzerland is proud to support the H2 project in the 2024/25 academic year with products, services, and expertise.

Team Cellsius H2 2023/24

At the end of September 2024, we had the pleasure of attending the project rollout at the Swiss Innovation Park in Dübendorf. The team, consisting of 10 focused students and an equal number of freelancers, informed sponsors, supporters, and other interested parties about the current status of the hydrogen-powered aircraft project and introduced the new project team for 2024/25.

A highlight was the displayed aircraft chassis from the manufacturer Sling, which is being specifically modified for the future integration of hydrogen tanks. Thanks to the extended wings, it will be possible to safely accommodate the tanks and, importantly, achieve the necessary lift. Afterwards, we had the opportunity to witness a test of the engine with a self-developed inverter, where the required power was primarily supplied by the fuel cell.

After assembling the motor and mounting it on the test stand, the team successfully ran the electric motor for the first time in the summer of 2024, powered by self-produced, emission-free electricity. While the motor components were developed and manufactured by an industry partner, all the mechanical parts, including the cooling system, were designed by the team themselves. As a result, they created an electric motor weighing only 35 kg, with an output of over 100 kW. The fuel cell system was also developed with the support of various companies and significant in-house effort.

You can find the video of our impressions from the rollout and the inverter tests here:

Moving Forward with Hydrogen-Powered Flight

The current team continues to work intensively on the implementation of an alternative hydrogen propulsion system for a light aircraft. This system is composed of various components designed to enable efficient and environmentally friendly flight. A large portion of the necessary parts are being developed in-house by CELLSIUS. To overcome technical challenges, the team draws on the support of experts and freelancers. The goal is to achieve a flight time of up to two hours and a range of 200 kilometers by the next rollout.

 

 

A Success Story

CELLSIUS launched its first major project in 2020 with the e-Sling, a battery-powered aircraft that successfully completed its maiden flight in 2022. For the past two years, the focus has shifted to the H2 project, which is developing hydrogen propulsion for light aircraft. Hydrogen offers a much higher energy density compared to batteries, enabling longer flight ranges.

Ensuring Safe Testing

Swagelok supports the team with its expertise in hydrogen technology. Our valves, ball valves, and pressure regulators are currently installed on the test stand, which is housed in a mobile container, as well as in the hydrogen tank supply line. To ensure that the products are installed correctly and safely, we invited all team members to participate in one of our Swagelok Essential Safety Training sessions.

Leak tightness plays a crucial role, especially with hydrogen, the smallest molecule. To ensure safety, we rely on 316 stainless steel with increased chromium and nickel content. This stainless steel contains at least 17% chromium and 12% nickel, exceeding ASTM minimum standards, significantly reducing the risk of hydrogen embrittlement.

Here is an overview of the products in use:

Pressure regulators (K-Serie)

Pressure gauge (PGI)

Ball valves (Serie 40)

Check Valves (Serie C)

Full metal hoses (Serie FJ)

Safety valves (Serie PRV)

various pipes and fittings, as well as hand tube benders.

We will regularly report on the progress of the project on this page and our Linkedin profile and wish the ETH Zurich team every success in the realization of the Cellsius project H2.