Market Connector: Harsh Environment Hybrid-Electric Propulsion Systems
All-electric propulsion technologies are poised to redefine small and large next-generation vehicle systems throughout the military and aerospace markets with the potential to deliver reliable, high-performance power to harsh-environment applications and provide other significant operational benefits. However, due to current energy density constraints and other technological limitations, all-electric technology isn’t yet totally feasible for some large complex vehicle systems such as armored vehicles and large aircraft.
While purely electric propulsion remains the goal for larger mission-critical platforms, hybrid-electric systems offer a near-term solution for integrating advanced electrical technologies into legacy and next-generation designs.
Who Are the Leading Developers of Hybrid-Electric Systems?
Many of the leading developers and manufacturers in the military and aerospace markets are working on scaling hybrid-electric systems for use in large vehicle platforms that operate in harsh environments.
In defense, the U.S. Army is collaborating with developers to produce prototypes of hybrid-electric powertrains for ground vehicles, including for future vehicular platforms within the Next Generation Combat Vehicle (NGCV) program. Similarly, the U.S. Navy and Air Force are exploring hybrid-electric options for ships and aircraft.
Throughout commercial air, companies like Boeing and Airbus are leading efforts to integrate hybrid-electric technologies into regional aircraft platforms. Agencies and organizations such as NASA and the European Union's Clean Sky program are conducting testing of hybrid-electric propulsion systems too.
These are just a few of the key players active in this evolving space.
What Benefits Could Hybrid-Electric Propulsion Bring for Larger Systems?
Hybrid-electric propulsion is viewed as a viable steppingstone toward full-electric power. Such technology could potentially deliver multiple operational benefits to large vehicular platforms.
A hybrid-electric system works by combining an internal combustion engine with one or more electric motors, high-voltage power electronics, and advanced energy storage units such as lithium-ion batteries. In a hybrid-electric powertrain, the mechanical source (turbine or internal combustion unit) provides baseline continuous power, while the electric motor(s) deliver instantaneous torque for takeoff, acceleration, or rapid load changes.
For instance, a hybrid-electric aircraft propulsion system might use a pair of 500 kW electric motors to increase lift during short-field takeoffs and reduce the aircraft’s need to spool up its turbines to full power. On a hybrid-electric naval vessel, a multi-megawatt electric motor integrated into the propulsion shafting could allow for finer control of speed and torque to enable silent cruising or immediate acceleration. Ground vehicles, such as select vehicle platforms within the U.S. Army’s NGCV program, may employ hybrid-electric powertrains that would efficiently distribute power from a central diesel engine to multiple electric traction motors to improve the vehicle’s responsiveness. This would be a major benefit for large, heavy armored vehicles weighing more than 50 tons.
Where Are Hybrid-Electric Powertrain Systems Being Developed?
Development of hybrid-electric powertrain systems is taking place around the globe.
In North America, NASA’s Electric Aircraft Testbed (NEAT) in Ohio is evaluating megawatt-class hybrid-electric powertrains to be used for future regional aircraft, while the U.S. Army is assessing hybrid-electric combat vehicle prototypes.
In Europe, companies such as Airbus and Rolls-Royce have conducted tests such as the E-Fan X demonstrator aircraft. The purpose of the E-Fan X was to test the effectiveness of hybrid-electric aircraft technologies. Although the E-Fan X was discontinued, other research and development initiatives are ongoing and the project provided valuable insight.
When will Hybrid-Electric Systems Be Ready?
Hybrid-electric configurations are expected to begin entering service on select specialized platforms over the next five to ten years as energy storage solutions continue to improve and power electronics achieve even better efficiency.
In the near term, smaller platforms and applications requiring less sustained energy output—such as regional aircraft, unmanned aerial systems, and light combat vehicles—are likely to adopt hybrid-electric systems first. This is due to the lower energy demands and the feasibility of integrating current battery technologies.
For larger platforms, such as main battle tanks, heavy combat vehicles, and large aircraft, hybrid-electric adoption is contingent on further advancements in battery energy density and thermal management. These technologies are currently under development with prototypes being tested to assess performance in real-world operating conditions. As these barriers are overcome, hybrid-electric systems will gradually be scaled into more complex and demanding mission-critical platforms, potentially becoming mainstream electrification solutions within the next decade.
Why Are Hybrid Electric Systems Being Developed for Larger Systems?
BAE Systems plans to develop a hybrid-electric version of its Armored Multi-Purpose Vehicle (AMPV), which is replacing the U.S. Army’s decades-old M113 Armored Personnel Carrier. AMPV is part of the NGCV family.
While hybrid-electric propulsion offers a pathway toward full-electric power, the technology also has the potential to provide substantial operational advantages. Hybrid-electric systems provide multiple performance enhancements to vehicular platforms including providing instant torque for acceleration, short-field takeoffs, or rapid speed adjustments. Hybrid systems, by offering distributed power and torque on demand, can also improve acceleration, reduce engine wear, and simplify maintenance. For example, a hybrid-electric military ground vehicle might reduce engine operating hours over its lifecycle due to reduced idling, regenerative braking, and optimized engine operation. These advantages are particularly valuable for mission-critical platforms that undergo significant operating hours, often in harsh operating conditions.
The modularity and scalability of hybrid-electric architectures also makes them adaptable to both legacy and next-generation designs. This allows for the gradual electrification of fleets without requiring complete system overhauls. The U.S. Army demonstrated this in recent years with the unveiling of a hybrid prototype of its Bradley Fighting Vehicle — a nearly 45-year-old armored vehicle platform. The possibilities for retrofitting existing platforms with hybrid-electric capabilities are endless.
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