GENESIS

POWER & PROPULSION DESIGN – MAXIMISING YOUR MISSION

At CAeS we can support your full propulsion system design and optimise it to achieve your mission profile, integration, and certification.

Through multi-physics modelling and simulation, we can explore all powertrain and propulsion architectures to ascertain both environmental, safety, payload power demands and aircraft performance.

Our recent studies have explored retro-fit of hydrogen-electric and hybrid power derivatives across a wide range of platforms, from EVTOLs to UAVs, helicopters, CS-23 and CS-25 aircraft.

We specialise in fuel cell propulsion system design, build, and test. With our expansive eco-system, we can also support system and supplier selection, system control, thermal management, fuel distribution and control, fuel storage and manufacturing and assembly.

CORE POWERTRAIN CAPABILITIES

Fuel Cell Propulsion System Design

Using full multi-physics, model-based systems engineering to accelerate and optimize the powertrain and build resilience. System integration with path to virtual certification

Propulsion (e-Motor, control, Propeller)

Noise reduction, highly efficient system integration, thermal management and control. Working with key partners

Fuel Cell Stack & Balance of Plant (HECS)

Adaptable fuel cell partners (LTPEM & HTPEM / HTSOX) key differentiation in cathode/anode and electrical BOP integration for system efficiency and mass reduction (currently 1kW/kg)

Hydrogen Distribution & Control

Pressure regulation, H2 refuelling, safety and segregation.

Thermal Management

Highly efficient, fully integrated. Transition to additive manufacture to reduce mass, aid structural integration

Hybridisation

Combining battery technologies to extend range and manage peak power demands and recharge optimising turn-around times

System Control

Aero-Native FADEC development, system monitoring, safety segregation

Hydrogen Storage

Adaptable Hydrogen storage, initially gaseous hydrogen (GH2), transition to passive liquid hydrogen (LH2) and metal hydride storage solutions. Structural or integrated storage tanks

Manufacturing & Assembly

State of the art modular manufacturing with adaptable modular build, test and validation. Pilot line facility development to support scalability and expansion

CASE STUDY: PROJECT FRESSON

Developed for passenger aircraft, the powertrain represents a substantial step forward in aero-native modular, scalable zero-emission propulsion system. The technology developed provides a highly adaptable architecture designed for aerospace, certification. The technology provides highly efficient performance, low maintenance and low, total cost of ownership.

OUT PERFORMING CONVENTIONAL TECHNOLOGY

Hydrogen significantly exceeds the performance of battery-only solutions. Customer led studies have demonstrated opportunities to substantially increase mission range. The unique capability of the powertrain provides opportunities for distributed propulsion, high altitude, low noise, low thermal signature and contested logistics.

BATTLE OF BRITAIN MEMORIAL FLIGHT

CAeS and its predecessors supported the UK’s Battle of Britain Memorial Flight for 40 years.

In that time, we have developed avionics modifications, structural repairs and provided Independent Technical Evaluation of third-party modifications.  We have also provided continual design, airworthiness and safety advice to structures and systems for the Flight’s fleet of Spitfires and Hurricanes.

SAAB 340

CAeS supported the design, development, integration and installation of a wide range of equipment for this unique aircraft modification.

CAeS also delivered the certification process, including flight testing.

Complex Flight Test Instrumentation (FTI) suite measuring all flight control movements, processes the data, and displays it directly to each student

New equipment rack housing data acquisition and management equipment (installed Data Acquisition Computer,
Inertial Measurement Unit, Sideslip Vanes, Navigation System, GPS Splitters)

Cockpit interface in centre pedestal that allows full control of the FTI equipment, battery isolation, master switch, WiFi
switch, etc.

Charging for the students’ tablets via USB or 240V AC.

Camera System for external forward view, cockpit view, and wing view

WiFi System supporting wireless data transmission inside the passenger cabin (including T-PED testing for compliance demonstration)

Installation of a passenger door in the rear bulkhead to make the cargo compartment accessible in flight

Installation of a FLARM Safety System, enhancing situation
awareness for the flight crew

Intercom headset sockets for classroom demonstrators

Certification Basis included Certification Review Items for
“Lithium Battery Installations” (CRI F-04) and “WLAN and Interfacing (T-)PEDs” (CRI F-01)

WEAPONS INTEGRATION

CAeS was contracted by Thales to support the integration of FASGW(L) system and by the MOD to support the integration of legacy Stingray torpedo and depth charge systems onto the Augusta Westland Wildcat helicopters. We also worked alongside MBDA who were supporting the FASGW(H) system and Leonardo helicopters who operated the helicopter.

Defensive Aids Integration

Supporting the integration of defensive aids onto the Chinook Mk5 and Mk6 helicopters and F-35.

Data collection was conducted using bespoke CAeS hardware that was manufactured in collaboration with UK MOD to support flight trials. The hardware consists of an array of data loggers and sensors fitted to a standard Type 118 flare case. This reduces minimal installation effort into standard flare magazines with minimal interference with aircraft systems that  enables faster safety assessments, clearance and turnaround during trials.

Boeing X-48 B/C

11 years of development with NASA, US Airforce and Boeing to design fully representative systems.
CAeS designed and built the X-48 B and C variants in the UK.
Blended wing concept design, considered a contender for future aircraft.
CAeS developed to test aerodynamic characteristics near stall speeds.​
CAeS designed the aircraft systems and ground station for piloting the vehicle.​
CAeS built the flight test demonstrator, support wind tunnel testing.
CAeS supported 7 years of flight testing
The X-48B, is the unmanned X-plane with the most sorties – 130.

AQUILLA

Experimental ground vibration test of the air vehicle to allow:​​

Validation of finite element model – mass, stiffness and interfaces​​

Validation of flight control model – quantify any coincidences of resonances with flight control frequencies​​

Low frequency GVT to assure the aero-elastic and stability​

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42 m wingspan, but extremely light​​

Modes expected at very low frequencies​​

Special low frequency instrumentation acquired​​

Suspension springs designed and manufactured for the test

ISTAR PLATFORM

Support to the Certification of modifications to CAA/DAOS Approvals​

CAeS provides structural and aerodynamic leads for the ‘major’ modifications involved.​

Design Services including,​

Mechanical and electrical system design​

Stress analysis (static, fatigue and damage analysis)​

Icing Predictions ​

Modification to Pressure Bulkhead​

Weight and Balance Reports​

Flight Performance Determination​

Flight trials​

Certification​

OLM support​

Wind tunnel testing​

Provision of CVEs and signatories

WATCHKEEPER

Support Agreement with U-TacS ​

Elbit (Silver Arrow)/Thales JV​

Support/advice to Elbit on UK MoD certification.​

Review of all certification documentation​

Major step forward in certifying UAV’s for flight in UK airspace.​

Load case analysis on entire vehicle​

Modifications to aircraft.

BAE SYSTEMS

CAeS was contracted by BAE Systems to design and certify various complex modifications on the FAAM BAE 146 Airborne Laboratory under our BCAR A8-21 approval. The aircraft is extensively used for atmospheric research across the world. CAeS modifications include various external apertures for sensors, cameras, and antennas as well as internal modifications for operator consoles, avionics, and supporting structures.

https://www.faam.ac.uk/​

SAFRAN- PROJECT BETA

In 2025, Safran central technologies (Paris) commissioned CAeS to support the development of their own hydrogen
programmes.

Working with the Safran team, CAeS are developing a 50-PAX regional aircraft to design, test and iterate with
new hydrogen powertrain pseudo technologies. With CAeS acting as both pseudo airframer and technology supplier, models with flight analysis provide the teams the opportunity to understand the environmental and
performance challenges associated with the state-of-the-art technology being developed. 

By exploring the integration of complex next generation system technologies through the product life-cycle, CAeS and Safran are able to accelerate early-stage developments, expose aircraft level technology challenges and increase system efficiency.

AIRBUS E-FAN X

CAeS was contracted by Airbus to support the E-Fan X project, a complex hybrid-electric flight demonstrator, which replaces one of the engines with a 2 MW electric motor.

CAeS designed and verified the structure to install and operate the jet engine/electric generator inside the fuselage of the BAe 146 flying testbed.

https://www.airbus.com/en/innovation/low-carbon-aviation/hybrid-and-electric-flight/e-fan-x

ROLLS ROYCE

CAeS was contracted by Rolls-Royce to verify the flight safety data under UK CAA E Conditions (CAP1220) for the all-electric “Spirit of Innovation” aircraft, which is the world’s fastest all-electric aircraft. It reached a top speed of 345.5 mph over a 3 kilometres stretch.

CAeS verified all the related documents including risk and safety assessments.

https://www.rolls-royce.com/media/press-releases/2021/19-11-2021-spirit-of-innovation-stakes-claim-to-be-the-worlds-fastest-all-electric-vehicle.aspx

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STRATUS 9

Californian-based private aviation and fractional ownership innovator Stratus 9 signed a deal with CAeS in February 2024 to create the United States’ first zero-emission fractional aircraft and co-ownership programme.

 

MONTE

MONTE is a global asset manager, founded with the sole ambition of financing sustainable regional transportation. Our partnership with MONTE allows us to offer extend financing options to operators when purchasing our modification kits or conversions.

 

EVIA AERO

A startup airline planning to operate exclusively sustainable aircraft, Evia Aero aims to reactivate regional markets and expand air travel in a scalable, sustainable and economically viable way. CAeS is one of the airline’s two technology partners.

DRONAMICS

Dronamics have developed the Black Swan, a middle-mile cargo UAV and have been granted both an IATA & ICAO operator designation and an AOC (Air Operator Certificate) in Europe. Although they will launch their operations with conventionally-powered UAVs, the MOU signed with CAeS in 2023 and the subsequent Letter of Intent for nearly 1300 CAeS hydrogen powertrains underlines their intent to transition to a sustainable solution for their platform.

 

TORRES STRAIT AIR

A 100% indigenously-owned air charter company based in the beautiful island community off the northern coast of Australia, Torres Strait Air has been operating Islanders for almost 10 years. A LOI signed with MONTE in September 2023 recognises the operator’s intention to convert its Islander fleet to hydrogen-electric propulsion.

https://torresair.com/

ISLE OF SCILLY GROUP SKYBUS

British reginal airline Skybus is owned by the Isles of Scilly Steamship Group (ISSG) and has been operating Islanders between the UK mainland and the Scilly Isles for over 30 years. ISSG signed a Letter of Intent with CAeS and Britten Norman in 2021 in recognition of their ambition to transition their air services to hydrogen.

AIR NEW ZEALAND

Air New Zealand are a major international airline renowned for their focus on sustainability.

Cranfield Aerospace were selected as Air New Zealand’s hydrogen technology partner on their Mission Next Gen Aircraft Programme which was created to accelerate the development of next generation aircraft technologies and the infrastructure required to make them a reality for commercial aviation in New Zealand.

https://www.airnewzealand.co.uk/

https://flightnz0.airnewzealand.co.nz/initiatives/mission-next-gen-aircraft