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600 kW airborne test shocks engineers — A super-hot fuel replaces hydrogen in this trial

by Laila A.
October 22, 2025
in Mobility
ZeroAvia hot fuel shocks engineers airborne test

Credits: ZeroAvia

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The airborne test of ZeroAvia’s 600 kW electric propulsion system (EPS) shocked engineers due to the unveiling of an unexpected substitute fuel option. A super-hot fuel, revealed during part of the testing process, could possibly replace hydrogen as a clean fuel source for the aviation industry. During the final testing phase, this new high-temperature synthetic fuel meant for combustion in hybrid electric systems was introduced and this introduction could indicate a full shift away from the hydrogen fuel cells used in ZeroAvia’s designs.

Why the airborne test shocks engineers and leaves them stunned?

The test had been conducted on the modified Jetcruzer 500E prototype aircraft. Earlier in the year, Jetcruzer International partnered with ZeroAvia as the company was developing the hydrogen-electric 500E aircraft for its 2028 launch, and the company required the EPS for internal testing. The final stage of testing led to the introduction of a new fuel source, which indicated how flexible the technology had become. The alternate fuel source was able to push the system beyond that shown by hydrogen tests while proving to be a sustainable and efficient fuel source in the process.

To date, the fuel alternative is referred to as “H3-X”. The change from hydrogen to this alternate fuel option came about after an agreement clause between ZeroAvia and another third-party partner that continues to remain confidential. As per the new fuel, it operates at a far higher thermal threshold than hydrogen and thus requires sophisticated cooling strategies. The beauty of this fuel alternative is that it offers a higher energy density.

A revolutionary breakthrough in electric aviation, thanks to ZeroAvia

ZeroAvia has already earned a great image thanks to the 600 kW EPS that is taking the aviation world by storm. This system is built around four 200 kW power inverters and features an electric motor capable of producing 2,200 rpm. The FAA also recently issued the G-1 issue paper to ensure certification for the 600 kW EPS. ZeroAvia surely is on track with its zero-emissions mission.

The results of the testing process, however, give ZeroAvia’s mission a whole new direction. The new fuel revolution does not signify the rejection of hydrogen, but a clear alternative paving the way forward to sustainable aviation.

How does Jetcruzer International fit into the sustainable aviation equation?

Jetcruzer International has been silently working on sustainable aircrafts for the future and is looking at a fully electric and hydrogen-powered future for aircrafts. JetCruzer International’s 500E prototype will be the first type-certified aircraft to fly with an all-electric propulsion system.

According to the CEO of Jetcruzer International, Victor Tao,  the partnership between ZeroAvia and Jetcruzer International is all about reshaping the industry, and in terms of adapting to the future, a new fuel source has become the new reality. Thanks to the Jetcruzer developments, 600 kW is set to soar the skies, not powered by hydrogen, but by a fuel source somewhat more powerful and experimental as well.

Hydrogen is still important to ZeroAvia’s mission for now

ZeroAvia has clearly outlined its mission. and for now and the new 136,000 sq. ft Propulsion Center of Excellence will be the core production site for all of ZeroAvia’s EPS units. The Jetcruzer 500E will also undergo preparation for more extensive flight testing in 2026, with a look at the hydrogen alternative that is heating up the discussions between ZeroAvia and Jetcruzer International.

Engineers may still be baffled by the new fuel discovery; however, this new fuel source could possibly heat up the future of all flights. With ZeroAvia continuing to expand and grow, a fuel source that is cleaner than hydrogen and more powerful than conventional fuels may very well be on the cards for the aviation industry. For now, hydrogen is still important to ZeroAvia’s mission.

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