Research Project Launched for Climate-Neutral Aviation Technologies
Kasaero GmbH is pleased to announce the launch of the MW-ULFK research project in cooperation with the Technical University of Applied Sciences Würzburg-Schweinfurt (THWS).
The project is funded under the German National Aeronautical Research Programme (LuFo), managed by the DLR Project Management Agency (DLR Projektträger), and will run from May 2026 to April 2029. As consortium leader, Kasaero is working together with THWS to develop a modular hydrogen fuel cell propulsion system for the climate-neutral retrofit of existing ultralight aircraft.
Together, the project partners are pursuing the goal of advancing sustainable propulsion technologies for General Aviation – while at the same time laying an important technological foundation for HYFLY H167, Kasaero's own product for hydrogen-electric aircraft
Background
Aviation is under increasing pressure to significantly reduce its CO₂ emissions. While alternative propulsion concepts are being developed for larger aircraft, practical retrofit solutions for existing ultralight aircraft remain limited.
One of the major technical challenges is integrating new propulsion technologies within the existing engine compartment while meeting strict requirements for weight, safety and certification. Although hydrogen-powered aviation is progressing rapidly, modular and certifiable propulsion systems suitable for multiple aircraft platforms are still largely unavailable.
Project Objective
The objective of MW-ULFK is to develop a modular hydrogen fuel cell electric propulsion system that enables the climate-neutral conversion of existing ultralight aircraft.
The main project objectives include:
- Utilisation of green hydrogen as a zero-emission energy source
- CO₂-free flight operation
- Integration of all propulsion components into the existing engine compartment
- Maximum propulsion system weight of 120 kg
- Modular architecture compatible with different ultralight aircraft platforms
- Standardised interfaces for simplified installation and maintenance
The modular system design is intended to provide a flexible retrofit solution for a wide range of ultralight aircraft.
Project Implementation
The project is jointly carried out by Kasaero GmbH, acting as consortium leader, and the Technical University of Applied Sciences Würzburg-Schweinfurt (THWS).
The project begins with a comprehensive analysis of aircraft requirements, engine configurations and certification regulations. Existing systems will then be evaluated to identify optimisation potential, followed by laboratory validation and flight testing.
Based on these findings, the complete propulsion system—including installation layout, piping, power electronics and control architecture—will be designed. During the integration phase, components will be manufactured, assembled and integrated into a prototype demonstrator. The completed system will subsequently undergo laboratory commissioning and extensive performance testing.
Project Partners
Consortium Leader
- Kasaero GmbH
Project Partners
- Technical University of Applied Sciences Würzburg-Schweinfurt (THWS)
The MW-ULFK research project is funded under the German National Aeronautical Research Programme (LuFo) and managed by the DLR Project Management Agency (DLR Projektträger).
Outlook
With MW-ULFK, the project partners are developing an innovative modular hydrogen fuel cell propulsion system that will enable existing ultralight aircraft to transition towards climate-neutral flight. The project represents an important step towards the decarbonisation of general aviation while establishing the foundation for future certifiable retrofit solutions.
The knowledge, technologies and integration methods developed within MW-ULFK will also directly support and accelerate the implementation of the HYFLY project, further strengthening the development of hydrogen-electric aviation technologies.
