Aurora Labs completes next-gen micro gas turbine for drone market

Aurora Labs has completed the design, build and test phase of its AU4 micro gas turbine engine, paving the way for commercialisation by mid-202.

The 40 kilogram thrust engine, designed for unmanned aerial vehicles (UAVs), leverages 3D printing technology to achieve significant advances in lightweighting, parts consolidation, fuel efficiency and simplified assembly.

“Our mission is to empower customers with cutting-edge propulsion systems,” said Rebekah Letheby, CEO of Aurora Labs, in a statement on Monday.

“The AU4 represents a major step forward in our technology journey and is now progressing towards potential first purchase orders.”

The company cited rapidly growing global demand for UAV propulsion systems, with approximately 5.42 million UAV units produced globally in 2024 and an expected compound annual growth rate of 16.3 per cent by 2030.

According to Aurora Labs, the AU4's design achievements include a significant reduction in part count, with 40 fewer components compared to conventionally manufactured counterparts. The case design now integrates the exhaust nozzle, engine mounts and gas seal, removing 23 parts, while the combustion chamber assembly has been refined with 17 fewer components.

The company reported a measured 6 per cent reduction in fuel consumption compared to traditional engine counterparts, achieved through novel geometry and AM-enabled weldments that contribute to superior thermal management.

Aurora Labs is currently engaging with international customers including global defence primes, with a focus on markets in Europe. The company is preparing its organisation for scaled manufacture, including export market accreditation, production quality control and metrology.

With both the AU2 and AU4 models now in its portfolio, Aurora Labs aims to address a substantial portion of the drone propulsion market within the global defence sector.

Picture: credit Aurora Labs