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US Army to Equip Gray Eagle 25M Combat Drone with GA-ASI's Powerful HFE 2.0 Engine.
On November 19, 2024, General Atomics Aeronautical Systems Inc. (GA-ASI) announced the completion of the final qualification tests for its advanced Heavy Fuel Engine (HFE) 2.0. Conducted at the company’s flight test facilities in El Mirage, California, these tests mark a major milestone in the development of a high-performance, low-maintenance engine designed for unmanned aerial vehicles (UAVs). Built for the Gray Eagle 25M, a medium-altitude, long-endurance (MALE) UAV, the HFE 2.0 delivers 200 horsepower and increases available electrical power by more than 50%, meeting the demands of multi-domain operations (MDO).
US Army Gray Eagle 25M Combat Drone to be equiped with GA-ASI's Powerful HFE 2.0 Engine (Picture source: GA-ASI)
On the same day, GA-ASI also announced the engine’s qualification process completion, paving the way for U.S. Army certification for integration into the Gray Eagle Extended Range (GE ER) unmanned aircraft systems and the modernized Gray Eagle 25M. This certification process will validate the engine’s compatibility with the operational requirements of these UAVs, replacing the aging 180-horsepower engines with a more powerful and durable version. With its 200 horsepower and enhanced electrical capacity, the HFE 2.0 is designed to meet the needs of multi-domain missions while reducing maintenance costs thanks to a 40% extended service life. Its integration into the Gray Eagle 25M, developed under a U.S. Army-funded program, marks a significant step forward in modernizing UAVs, making them better suited for future missions through increased autonomy and the ability to carry advanced payloads.
Completed on November 13, the three-week qualification campaign adhered to endurance standards set by the Federal Aviation Administration (FAA, regulation 14 CFR 33.49). This rigorous process included 2,450 full-power cycles and 50 hours of flight tests. The engine, which offers a 40% increase in service life compared to previous models, reduces maintenance needs while delivering optimal performance under demanding conditions. The enhanced dual brushless generator, developed in collaboration with General Atomics Electromagnetic Systems, further improves performance and enables the integration of advanced payloads for MDO missions.
The HFE 2.0 engine offers significant benefits to armed forces by enhancing the operational capabilities of UAVs like the Gray Eagle 25M. Its increased power output and 40% longer service life reduce maintenance needs, allowing for extended, maintenance-free missions critical to MDO. The engine’s enhanced electrical capacity supports advanced payloads, improving the UAV’s versatility for surveillance, reconnaissance, and precision-strike roles. Designed to replace aging engines, it ensures reliability and reduces logistical burdens, making it an essential upgrade for modernizing fleets and meeting evolving military needs.
David R. Alexander, President of GA-ASI, described these tests as “the culmination of an extensive durability and flight test program.” He added that the HFE 2.0 represents a key step in modernizing the Gray Eagle fleet, particularly by replacing the aging 180-horsepower engines in the Gray Eagle Extended Range UAVs. This engine is also central to the modernized Gray Eagle 25M, which is being developed under a U.S. Army-funded program to equip future UAV missions with the most advanced technologies.
Developed in collaboration with global propulsion technology leaders such as Cosworth and supported by GA-ASI’s internally funded research and development programs, the HFE 2.0 embodies innovation. With FAA endurance testing now complete, the engine is entering the U.S. Army’s certification process. This marks a step toward operational integration into the Gray Eagle fleet, reaffirming GA-ASI’s position at the forefront of UAV propulsion systems to meet the ever-evolving needs of modern military forces.
The development of the HFE 2.0 engine by GA-ASI spans seven years of intensive efforts, initiated as part of a self-funded research and development program. The project has benefited from strategic partnerships with propulsion experts such as Cosworth and General Atomics Electromagnetic Systems, who contributed to the advanced design of the dual brushless generator. The past 18 months have been dedicated to rigorous durability testing, including 2,450 full-power cycles and three test profiles totaling 200, 400, and 651 hours, before transitioning to flight tests in 2024. The final qualification phase, meeting FAA standards, concluded on November 13, 2024, paving the way for U.S. Army certification to integrate this engine into the Gray Eagle fleet.