The U.S. Naval Research Laboratory (NRL) has applied hydrogen tactics to U.S. Marine Corps field units, using hydrogen fuel cell technology to replace the heavy batteries and generators soldiers currently use to provide power.Napoleon once said that an army marches on its belly. In the 21st century, it would be more accurate to say that armies move by batteries. As soldiers increasingly rely on personal radios, computer networks, sensors, night vision goggles, forward-looking infrared scopes, advanced rifle scopes and man-portable drones, they are also increasingly carrying battery-powered ammunition belts or lugging generators and fuel drums across the nasty last mile of rugged terrain.
H-SUP powers communication links
No wonder so many soldiers often "lost" batteries while on patrol. To alleviate this problem, the U.S. Naval Research Laboratory is refining and field-testing hydrogen fuel cell technology originally used to power small drones. The system, called the Hydrogen Small Unit Power System (H-SUP), is designed to save the Marine Corps the same weight as an unmanned aircraft.
H-SUP is said to be lighter than batteries
This may sound like an exaggeration, but drones have limited range and endurance, especially when powered by electricity. Since batteries are heavy, weight remains a major factor even in hybrid systems. The same is true for Marines hiking through rugged terrain.
In this case, the H-SUP system is similar to the one developed for the hydrogen-powered H2 Stalker program, except that it is reinforced and repackaged into a set of waterproof plastic cabinets that contain the fuel cells, inverter, hydrogen storage and charging stations for various devices.
H-SUP module
The H-SUP is claimed to be more energy dense than batteries or traditional generators and therefore lighter, with an output of up to 1.2 kilowatts. It's more efficient, quieter, has a lower heat signature because it works by electrochemical reaction rather than combustion, and has a built-in glycol-based cooling system, making it harder for enemies to detect. With fewer moving parts than a generator, maintenance is easier and rated for up to 5,000 hours of operation.
Its modular construction also means it can be easily modified to suit specific tasks and can be connected to a vehicle's electrical system.
The H-SUP was field-tested in July 2022 at Marine Corps Base Lejeune, February 2025 at Marine Corps Air Station Yuma, and March 2025 at Marine Corps Bellows Training Area. Additionally, the U.S. Army tested it with the 101st Airborne Division at Fort Polk in May 2025. The results of these tests will be used to improve the system.
H-SUP designed to provide power to tactical units
"Warfighter feedback is a critical component of the technology development process and will be used to guide requirements definition and future research and development activities," said Capt. Joshua Ashley, science and technology analyst for the U.S. Marine Corps Expeditionary Energy Office (E2O). "E2O is the link between the warfighter and the lab, providing feedback to refine the system and accelerate acquisition."
H-SUP not only innovates, it also ensures we are powered and difficult to detect, increasing lethality. We ensured this technology would meet the needs of Marine Corps ground forces—quiet, efficient, reliable power to support expeditionary operations.
Source: NRL