Decarbonisation of the aviation sector is essential for achieving global-climate targets, with hydrogen propulsion emerging as a viable alternative to battery–electric systems for vertical flight. Unlike previous studies focusing on clean-sheet eVTOL concepts or fixed-wing platforms, this work provides a comprehensive retrofit evaluation of a two-seat light helicopter (Cabri G2/Robinson R22 class) to a hydrogen–electric hybrid powertrain built around a Toyota TFCM2-B PEM fuel cell (85 kW net), a 30 kg lithium-ion buffer battery, and 700 bar Type-IV hydrogen storage totalling 5 kg, aligned with the Vertical Flight Society (VFS) mission profile. The mass breakdown, mission energy equations, and segment-wise hydrogen use for a 100 km sortie are documented using a single main rotor with a radius of R = 3.39 m, with power-by-segment calculations taken from the team’s final proposal. Screening-level simulations are used solely for architectural assessment; no experimental validation is performed. Mission analysis indicates a 100 km operational range with only 3.06 kg of hydrogen consumption (39% fuel reserve). The main contribution is a quantified demonstration of a practical retrofit pathway for light rotorcraft, showing approximately 1.8–2.2 times greater range (100 km vs. 45–55 km battery-only baseline, including respective safety reserves). The Hawk demonstrates a 28% reduction in total propulsion system mass (199 kg including PEMFC stack and balance-of-plant 109 kg, H2 storage 20 kg, battery 30 kg, and motor with gearbox 40 kg) compared to a battery-only configuration (254.5 kg battery pack, plus equivalent 40 kg motor and gearbox), representing approximately 32% system-level mass savings when thermal-management subsystems (15 kg) are included for both configurations.
Sajid et al. (Sat,) studied this question.