At Orbital UAV, combustion efficiency begins with precise fuel atomisation

Our FlexDI™ air-assisted direct injection system atomises fuel to ~8 µm droplets, compared to ~120 µm in conventional systems.

28/10/2025

Chris Bodycat

Our FlexDI™ air-assisted direct injection system atomises fuel to ~8 µm droplets, compared to ~120 µm in conventional systems. This ultra-fine distribution enables cleaner, faster combustion, improving thermal efficiency and reducing specific fuel consumption up to 40 % at cruise.

The system provides automatic altitude and temperature compensation, reliable cold start at –30 °C, and consistent operation from sea level to 20,000 ft. FlexDI™ supports heavy fuels (JP-5, JP-8, Jet A/Jet A-1) and gasoline, with electronic oil metering and closed-loop ECU control ensuring precise mixture formation and lubrication under varying load conditions.

Our best-in-class BSFC allows UAV operators to minimise fuel weight, maximise payload, and extend range, critical factors for endurance missions.

Validated through three times FAR 33.49 150-hour endurance testing and MIL-STD-810H qualification, FlexDI™ delivers reliable power when it matters most.