How hydrogen drones enable BVLOS missions

As drone technology advances, the next frontier for unmanned aerial vehicles (UAVs) lies in extended missions – those that go far beyond what battery-powered drones can currently achieve. One of the key enablers of these capabilities is hydrogen fuel cell technology. From infrastructure inspection to emergency response, hydrogen drones are proving essential for Beyond Visual Line of Sight (BVLOS) missions.

The UK’s first hydrogen-powered BVLOS flight

In a UK-first trial, Intelligent Energy’s hydrogen fuel cell technology successfully powered a BVLOS drone flight over Eryri National Park and 10km offshore, marking a milestone for UAV endurance and operational freedom.

The project, led by BT, with support from uAvionix, Skyfarer, and Intelligent Energy, showcased how a fuel cell-powered drone, paired with resilient communications infrastructure, could maintain control beyond a pilot’s line of sight. The drone used in the trial—a 25kg six-rotor UAV—was powered by Intelligent Energy’s IE-SOAR™ hydrogen fuel cell system, which delivered extended flight time and zero emissions.

Advanced connectivity was provided via SkyLine, combining protected C-band radio, cellular, and satellite links to ensure uninterrupted command and control over remote terrain.

Why hydrogen for BVLOS?

Hydrogen drones offer a compelling alternative to battery-powered UAVs, especially for long-distance and high-payload applications. Key advantages include:

• Extended Endurance: IE-SOAR systems offer up to three hours of continuous flight, far exceeding the capabilities of lithium-ion batteries.
• Rapid Refuelling: Hydrogen refuelling takes minutes, enabling faster turnaround times for repeat missions.
• Higher Payload Potential: Greater energy density allows UAVs to carry heavier sensors or delivery packages without compromising range.
• Zero Emissions: Water vapour is the only by-product, making these systems ideal for environmentally sensitive operations.

These advantages are especially important for commercial UAV operators seeking to scale operations or expand into more demanding mission profiles.

Unlocking real-world applications

Hydrogen fuel cell powered drones are already being deployed in several BVLOS use cases:

• Infrastructure inspection: In partnership with Cyberhawk, Intelligent Energy’s UAV systems support long-distance power line inspection in remote locations – reducing risk, cost, time, and emissions.
• Emergency response: With robust range and quick deployment, hydrogen UAVs can reach disaster zones or hard-to-access environments faster, supporting search and rescue or communications relay.
• Parcel delivery: The ability to fly further with heavier payloads opens doors to logistics in rural, island, or high-risk areas.

Regulation and the BVLOS opportunity

BVLOS operations are currently limited by regulations in many countries. However, successful demonstrations like the UK trial – combined with advances in fuel cell reliability and command-and-control systems – are helping regulators understand how to integrate hydrogen UAVs into national airspace safely.

The UK Civil Aviation Authority (CAA) is actively exploring frameworks to enable wider adoption of long-range UAV missions. Hydrogen-powered drones, with their extended reach and low emissions, are likely to play a central role in future standards for safe and sustainable BVLOS flight.

Designed for demanding UAV applications

The IE-SOAR product range includes modules from 800W to 2.4kW, tailored for high-performance UAVs across fixed-wing, rotary, and hybrid platforms. Lightweight, compact, and air-cooled, these systems are engineered for industrial-grade reliability in diverse operational conditions.

From powerline inspections to parcel drops, hydrogen-powered UAVs are setting new standards in endurance and operational flexibility.

A step closer to certifiable BVLOS services

As demonstrated by the BT-led trial, combining multi-layered connectivity and hydrogen power creates a resilient, scalable foundation for BVLOS operations. It’s not just a technical achievement -it’s a signal that market-ready, certifiable hydrogen UAV services are on the horizon.

As Andy Kelly, Head of Product Line at Intelligent Energy, noted:

“The combination of reliable long-range communications and the extended flight time of our IE-SOAR system shows how hydrogen power can move UAV operations to the next level – enabling real-world, long-distance missions that battery systems simply can’t deliver. It’s a step towards certified, market-ready services that will allow drones to fly further, carry heavier payloads and operate safely in remote areas.”

FAQs

What is BVLOS and why does it matter?
Beyond Visual Line of Sight (BVLOS) refers to drone operations that go beyond the pilot’s direct visual range. BVLOS enables longer missions, more automation, and a wider range of commercial applications, but requires advanced safety and control measures.

How long can a hydrogen fuel cell drone fly?
IE-SOAR systems can power drones for up to 3 hours, depending on payload, flight profile, and conditions. This is significantly longer than most battery-powered UAVs, which often max out at 20–40 minutes.

Is hydrogen safe to use in drones?
Yes. When properly stored and integrated, hydrogen is a safe and well-understood energy source. Intelligent Energy’s UAV fuel cells are designed with safety and reliability at their core.

What applications benefit most from hydrogen drones?
Long-range inspection, search and rescue, logistics, and remote mapping are key sectors where hydrogen drones outperform traditional battery models.

Discover how Intelligent Energy’s hydrogen fuel cells can help you extend UAV range, improve sustainability, and unlock new commercial use cases. Get in touch with our experts today.