Australian firms to develop hydrogen fuel cell cooling for long range, zero emission eVTOLs

AMSL Aero’s Vertiia aims to be the world’s most efficient long-range, zero emissions, electrical VTOL aircraft.

Conflux Technology, a worldwide pioneer in the design, engineering, and production of additively manufactured heat exchangers, has announced a partnership with AMSL Aero—an Australian aerospace company developing the world’s most efficient, long-range, zero-emission electric Vertical Take-Off and Landing (VTOL) aircraft.

In the initial phase of the project aimed at developing a hydrogen fuel cell cooling system for AMSL Aero’s Vertiia VTOL aircraft, Conflux created three cutting-edge heat exchanger concepts. These designs focused on reducing weight and size while effectively managing constant heat loads and minimizing drag, enabling flight ranges of up to 1,000 kilometers.

The initiative has now entered its second phase, which involves refining the design and producing a complete proof-of-concept assembly to assess its performance within Vertiia’s hydrogen-powered propulsion system.

“Hydrogen fuel cells are a game-changer in Australia’s journey toward clean energy solutions. We're excited to apply our heat exchange technology to improve the efficiency and performance of Vertiia’s hydrogen fuel cells. This partnership is helping to drive innovation in sustainable aviation,” said Michael Fuller, CEO and Founder of Conflux Technology.

The Conflux cooling system is being tailored to handle the intense, fluctuating heat generated during vertical take-off, landing, and hovering phases of flight. Key constraints for hydrogen-powered aircraft include weight, efficiency, and compact design. Leveraging the design flexibility of additive manufacturing, Conflux’s heat exchangers are both lightweight and space-efficient. Their patented thin-walled structures deliver superior thermal performance with minimal aerodynamic drag.

AMSL Aero Chairman Chris Smallhorn stated:

“With Vertiia, we’re creating a hydrogen-electric aircraft capable of record-breaking range and high speeds akin to Formula 1. Conflux Technology, known for its innovation in both motorsports and aerospace, is the ideal partner for this venture.

“AMSL Aero is firmly committed to continuing Vertiia’s development in Victoria, and Conflux stands as one of the state’s industrial leaders, making the Avalon Air Show the perfect venue to announce our collaboration.”

Simon Coburn, Hydrogen Systems Engineer at AMSL Aero, added:

“We’re thrilled to join forces with Conflux, whose rapid innovation pace and AS9100D-certified manufacturing and quality standards will be crucial in helping Vertiia become the world’s first hydrogen-powered VTOL for long-range passenger travel. Together, we are shaping a future where clean energy and advanced engineering propel aviation toward a more sustainable path.”

This partnership marks a significant expansion of Conflux’s role in aerospace, utilizing additive manufacturing to produce high-performance heat exchangers for the next generation of aviation. Their technology now supports a range of applications, including cooling systems for propulsion, gearboxes, avionics, environmental controls, and power electronics. As the push for greener technology intensifies, additive manufacturing is redefining performance standards by delivering thermal management capabilities beyond the reach of traditional techniques.