Airbus backs 3D-printed heat exchanger to cool hydrogen-electric jets

Airbus is advancing its hydrogen-electric aviation efforts through collaboration with Conflux Technology, which is developing a next-generation 3D-printed heat exchanger critical for thermal management in megawatt-class hydrogen fuel cell systems. This lightweight, high-performance component, created using additive manufacturing and validated with Computational Fluid Dynamics (CFD) modeling, is designed to regulate the substantial heat generated by hydrogen fuel cells, ensuring safe and efficient operation of Airbus’ ZEROe hydrogen-electric propulsion systems. The ZEROe program aims to produce the first zero-emission commercial aircraft powered by hydrogen fuel cells, targeting entry into service by 2035, with water vapor as the only emission. Despite technological progress, including successful testing of a 1.2-megawatt fuel cell engine and advancements in liquid hydrogen storage, the ZEROe program has faced delays, pushing the timeline back by 5 to 10 years and reducing its budget by 25%. These setbacks stem from the complexity of developing the propulsion technology and establishing a global