The aviation industry contributes significantly to global greenhouse gas emissions, accounting for approximately 2.5% of worldwide CO₂ emissions. Yet, the aviation industry faces challenges with limited options to reduce carbon emissions.
Hydrogen has emerged as a promising option for clean aviation fuel thanks to its zero-emission potential. However, storage remains one of the primary barriers to its adoption in aviation. Its low volumetric energy density means it takes up significant space as a gas and traditional storage solutions rely on heavy materials like metal to prevent leaks. These weighty tanks are impractical for aircraft, where every kilogram counts.
In response to this challenge, aerospace leader Quickstep and researchers at UNSW, are collaborating to develop a revolutionary lightweight hydrogen storage system. This breakthrough innovation is poised to unlock hydrogen’s potential as a clean energy source for aviation.
The SMART Hydrogen Tank
Supported by the Trailblazer for Recycling and Clean Energy (TRaCE) initiative, the SMART Hydrogen Tank represents a paradigm shift in hydrogen storage technology. SMART stands for Sensor Managed Advanced Refueling Tank, focusing on integrating sensors and advanced manufacturing technologies into hydrogen storage tanks.
Unlike traditional designs, which rely on weighty liners to prevent hydrogen leakage, this advanced tank leverages lightweight carbon-fiber composites to ensure both durability and efficiency.
Automated manufacturing processes enhance large-scale manufacturability, while the tank’s design maintains the structural integrity required for aerospace applications. By addressing the two challenges of weight and airframe integration, the SMART Hydrogen Tank paves the way for hydrogen-powered aviation.
“Optimising hydrogen storage is one of the most pressing challenges in the aviation sector,” said Scientia Professor Gangadhara Prusty from UNSW’s School of Mechanical and Manufacturing Engineering. “As a small molecule, hydrogen can easily escape. That’s why most tanks include a metal or polymer liner, but this solution adds weight. By eliminating the need for heavy liners, we’ve significantly reduced the tank’s weight, creating new opportunities for increased fuel capacity and payload.”
Leveraging drones as a test platform and a practical solution
Hear from the team behind the SMART Hydrogen Tank and get a closer look at the hydrogen-powered drone:
The SMART Hydrogen Tank’s capabilities are being demonstrated through its integration into a hydrogen-powered drone. Built directly into the drone’s structure, the tank efficiently stores the hydrogen needed to power its fuel cell or hydrogen engine. This design mirrors the functionality of an electric battery but offers extended flight times and higher payload capacities due to hydrogen’s superior energy density.
Drones provide an ideal platform for implementing this technology. Their smaller size and lower development costs allow for rapid prototyping, trials, certification and large-scale manufacture. Furthermore, they validate the tank’s safety and performance in real-world conditions, such as during flights with varying loads. By developing and testing these tanks on drones, researchers can demonstrate the technical and economic feasibility of hydrogen as a fuel. Once the concept is proven, the technology can be scaled up for use in larger aircraft or other aerial vehicles, paving the way for a significant impact on the aviation sector’s decarbonisation.
Ashim Panta, Design Lead at Quickstep, explains: “Hydrogen-powered drones are more than just test platforms; they offer real-world solutions with their superior energy density compared to batteries. This advantage translates to longer flight times and higher payload capacities, enabling critical applications like delivering medical supplies, vaccines, and emergency equipment to remote or disaster-hit areas where conventional transport and battery drones fall short. They also provide scalable solutions for agricultural monitoring, environmental surveys, and infrastructure inspections, reducing dependence on carbon-intensive vehicles while enhancing efficiency and accessibility.”
Enhanced safety with smart sensors
In addition to its lightweight design, the hydrogen tank incorporates fiber-optic sensors developed by UNSW researchers. These sensors monitor the tank’s condition in real-time, tracking strain, integrity, and atmospheric conditions during flights to ensure safety and reliability.
“Our tank’s design doesn’t just reduce weight; it enhances reliability by providing real-time data on performance to enable proactive responses under various flight conditions,” explained Professor Garth Pearce from UNSW’s School of Mechanical and Manufacturing Engineering.
A Model for Industry-Academia Collaboration
The SMART Hydrogen Tank is a testament to the power of collaboration between academia and industry. UNSW researchers contribute expertise in advanced materials and monitoring technology, while Quickstep brings the engineering know-how to ensure the design aligns with scalable manufacturing and real-world aerospace applications.
“Close collaboration has been the key to tackling technical challenges,” said Ganga. “It’s partnerships like this that drive meaningful innovation.”
Backed by TRaCE, the project exemplifies how research and industry can unite to create impactful, scalable solutions that push the boundaries of sustainability.
By combining innovative materials, advanced manufacturing techniques, and cutting-edge sensor technology, the SMART Hydrogen Tank lays the groundwork for the broader adoption of hydrogen in both drones and larger aircraft and represents a significant step forward in the quest for decarbonised aviation.
