Orbital UAV stands at the forefront of developing integrated heavy fuel engine systems tailored for both military and commercial drone applications. Specializing in Group 2 and 3 tactical UAS (unmanned aerial systems), we deliver cutting-edge propulsion solutions that empower global defense forces too deploy advanced unmanned ISR (intelligence, surveillance, and reconnaissance) and logistical support on the battlefield.
With four decades of expertise in crafting refined engine technologies and a 15-year track record as the global frontrunner in spark-ignited heavy fuel propulsion, we collaborate closely with leading tactical UAV manufacturers, including Insitu and Textron.
FlexDI Technology
Innovative Spark Ignition for Heavy Fuel UAV Engines
Our spark-ignited heavy fuel engines leverage our unique FlexDI technology, which incorporates a spray-guided direct fuel injection mechanism that uses injected air for fuel atomization. This meticulous atomization enhances surface area and optimizes vaporization.
Additionally, we have engineered an aerospace-grade smart electronic propulsion management system that offers a suite of UAV-specific features, including anti-stall mechanisms, power management, speed regulation, and engine safeguarding.
Our engines are meticulously designed to ensure efficient and dependable combustion of various heavy fuels such as JP5, JP-8, and Jet-A1, aligning with the single-fuel policies increasingly adopted by defense forces globally. Furthermore, all Orbital heavy fuel engines are compatible with gasoline, enhancing their versatility.
Engine Offerings
50cc Heavy Fuel engine
The Orbital 50cc Heavy Fuel Engine features an air-cooled, two-stroke, single-cylinder design, delivering 3.7 hp (2.8 kW) at 6500 RPM. Weighing only 3 kg, it can generate 250W of electrical power.
The operational capabilities of the 50cc HFE have been validated through over 150,000 hours of field service with Insitu. This engine is the preferred propulsion system for the insitu ScanEagle 3, a long-endurance tactical ISR drone utilized by the U.S. and Australian armed forces.
For further details on the 50cc Heavy Fuel UAV Engine, please reach out to us.
75cc Heavy Fuel Engine
The Orbital 75cc Heavy Fuel Engine employs an air-cooled, two-stroke, single-cylinder configuration, producing 5.2 hp (3.9 kW) at 6500 RPM. Weighing just 4.4 kg, it offers customizable electrical power outputs ranging from 300 to 500W to meet specific customer needs.
The 75cc HFE has been chosen for the Aerosonde MK4.7, a tactical hybrid VTOL sUAS designed for both land and maritime ISR operations. It has amassed over 650,000 hours of operational service with Textron.
For more information on the 75cc Heavy Fuel UAV Engine, please contact us.
150cc Heavy fuel Engine
The Orbital 150cc Heavy Fuel Engine is our newest engine in full production, featuring a horizontally-opposed twin-cylinder two-stroke boxer design. Weighing 6.4 kg, this MIL-STD-810H qualified engine can produce 11.5 hp (8.5 kW) at 6500 RPM, with customizable electrical power outputs ranging from 300 to 1000W.
This engine has successfully completed over 5000 hours of ground testing, alongside multiple 150-hour FAR33.49b durability assessments and 500-hour mission profile durability tests. It has been selected for Textron Systems’ Aerosonde MK4.8, a tactical hybrid VTOL UAS specifically designed to fulfill the U.S. Army’s Future Vertical Lift requirements.Additionally,it is indeed being supplied to a prominent defense contractor in Singapore.
For more information on the 150cc Heavy Fuel UAV Engine, please get in touch with us.
Facilities and Capabilities
Orbital UAV operates state-of-the-art facilities in Perth, Western australia, and Oregon, USA, equipped for design, embedded electronic control, manufacturing, and engine testing, as well as fuel and oil assessments and engine management systems.
Our key testing, development, and production capabilities include:
- Multiple engine test cells at each location
- In-house machining facilities
- Altitude simulation chamber capable of reaching 20,000 ft, with temperature control from -35°C to 65°C
- Semi-anechoic NVH room for noise evaluations
- Environmental Stress Screening, including HALT and HASS with simultaneous temperature and vibration
- Comprehensive metrology department
- Annual production capacity exceeding 600 new-build or MRO units at the Australian facility and over 240 at the U.S. facility
