You must be wondering, what exactly is hydrogen fuel cell (HFC) technology, and what is so good about it?  Hydrogen fuel is a clean fuel that is burned along with oxygen in an electrochemical power generator to generate electricity, and in the process, produces water and heat as by-products. What sets hydrogen fuel apart, however, is the fact that it serves as an alternative to diesel fuel in more ways than one: its fuel-cycle emits no pollutive exhaust, and through renewable energy, there contains no trace of greenhouse gas emissions. Vehicles that are powered by the hydrogen fuel cell, thus, significantly reduce our use and dependence on diesel oil and lower the chances of harmful emissions contributing to climate change. What started out as an experiment among startup companies and early projects is now dominating the commercial vehicle industry with many of the industry’s biggest players putting in large investments in the technology. 

How Does it Work?

Hydrogen fuel can be produced through several methods, and in the commercial vehicle industry, fuel is processed in a fuel cell that is composed of three main components: an anode, a cathode, and an electrolyte membrane. This type of fuel cell is called a Proton-Exchange Membrane Fuel Cell, or also known as a polymer electrolyte membrane (PEM) fuel cell, which is mainly reserved for transport applications and stationary and portable fuel cell applications. The PEM fuel cell does its job by passing hydrogen through the anode, at which hydrogen molecules are split into electrons and protons. The former ones take the path of a circuit in the fuel cell to generate electric current and excess heat, while the protons go through the electrolyte membrane. At the same time, the PEM fuel cell passes oxygen from the surrounding air through the cathode on the other side, where the oxygen meets with the protons and electrons to produce water molecules. This does not get any simpler than your run-of-the-mill science experiment in school!

What Are Fuel Stacks Then?

What lies in the heart of a fuel cell vehicle (FCV) is the fuel cell stack. Because fuel cells generate less than 1.16 volts of electricity each, they must be assembled atop one another to create a fuel cell stack in order to generate enough power to run a vehicle. The potential power that can be generated by a fuel cell stack largely varies and is dependent on the number and the size of the individual fuel cells of the fuel cell stack, as well as the surface area of the PEM. 

The Preferred Alternative

Hydrogen fuel cell has been proven to yield positive results for both the environment and the wallet in the long term. 

Reduction in Greenhouse Gas Emissions

Contrary to diesel fuel, which emits greenhouse gases (GHGs) and carbon dioxide (CO2) that are large contributors to climate change, the only by-products of vehicles–when fueled by pure hydrogen–are heat and water with the release of zero tailpipe GHGs. While it is possible for FCVs to still generate GHGs, depending on the production method, the GHGs emitted is still far less great than those emitted by gasoline and diesel fuel. FCVs also eliminate the maintenance costs that come with storing diesel fuel that may prove harmful later on. Many of the industry’s big players make use of environmentally benign hydrogen in their hydrogen fuel cell products to eliminate and prevent the harmful impact of fuel spillage or leaks and air pollution. 

Cutback on Vehicle Oil Dependence

Many companies have incorporated hydrogen fuel cells in their corporate sustainability programmes, and the industry is seeing a shift of focus from diesel fuel to environmentally friendly alternatives. With the industry soon to be saturated with FCVs, our dependence on foreign oil will be significantly reduced and eventually eradicated. Hydrogen can be extracted sustainably from domestic sources, such as natural gas and coal, as well as from renewable sources, such as water, biogas, and agricultural waste. From an economic perspective, this would allow us to be less affected by oil price hikes and drops in the volatile oil market. 

Lowering of Operational Costs

Hydrogen fuel cells require little to no maintenance as they eliminate the need to change, charge, and manage batteries, a maintenance check that is necessary for batteries, internal combustion generators, and the like. Hydrogen fuel cell units have a longer running time than do lead-acid batteries and, when power is running low, would not take more than five minutes to refuel. Companies that employ FCVs in their fleet benefit substantially from this as it reduces vehicle and personnel time, giving birth to a higher efficiency rate. This loss of regular maintenance saves not only money but labour, time, and the space for battery rooms as maintenance checks require optimal conditions. 

Increase in Energy Efficiency

 Hydrogen fuel cells are well known to be more energy-efficient than other forms of power. When a fuel cell vehicle is fueled by pure hydrogen, the hydrogen fuel cell has the potential to be up to 80-percent efficient. This means that the fuel cell converts up to 80 percent of the energy content of the hydrogen into electrical energy. The electric motor and inverter of the vehicle thus have the responsibility to convert that electrical energy into mechanical energy, with an average of 80 percent efficiency. Combined, this gives an overall 64-percent of increased efficiency when a vehicle is powered by a hydrogen fuel cell!

Increase in Durability and Reliability

Hydrogen fuel cells are notably more robust than other forms of fuel and can weather all types of conditions, from cold environments to harsh storms. This makes fuel cells a reliable asset to companies that engage commercial vehicles in tough environments. Additionally, because they do not have any moving parts, hydrogen fuel cells operate quietly even in the midst of a snowstorm! 

With environmentally friendly applications and time-consuming maintenance, we are beginning to see the boom of hydrogen fuel cell technology in the commercial vehicle industry, and with good reason! (MT)

(Credits / Sources: U.S Energy Information Administration, Hydrogenics, Toyota, Verdict Media, Stanford University, University of Nebraska, Fuel Economy, Plug Power) 

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Researchers at Chalmers University of Technology, in collaboration with industry partners, have published a study in Nature Communications demonstrating that reconfigurable battery pack architectures can extend electric vehicle battery operational life by more than 20 percent under specific conditions.

In conventional electric vehicle battery packs, cells are wired in a fixed series configuration, meaning the weakest cell dictates the overall capacity, performance and lifespan of the entire pack. The architecture evaluated by the Chalmers engineering team uses integrated electronic switches and a centralised battery management system to monitor individual cells or cell groups. When a cell experiences accelerated degradation or reduced capacity, the system bypasses the degraded unit while electric current continues to flow through the remaining functional cells.

Albert Skegro, a PhD student at the Department of Electrical Engineering at Chalmers University of Technology, said, "They must all move at the pace of the slowest person and stop when that person stops, regardless of how much energy the others have left. With the architecture we have modelled, the battery can instead bypass the cell that is causing problems and continue using the remaining cells."

Changfu Zou, Professor at the Department of Electrical Engineering at Chalmers, said, "Reconfiguration is not an on-or-off choice. It is a spectrum. Where a manufacturer chooses to position itself on that spectrum determines how much of the potential benefit can be realised."

In a representative modelling scenario featuring an 80 kWh battery pack driven 12,000 kilometres annually over an 18.8-year vehicle lifespan, the reconfigurable system deferred battery replacement by approximately 14 months. The researchers noted that the technology yields the highest performance gains in high-voltage vehicles, including 400-volt and 800-volt electric passenger cars and commercial trucks, where higher cell counts in series increase the statistical probability of individual cell variance.

A techno-economic analysis included in the study determined that implementing cell-level switching hardware increases initial pack production costs by approximately nine per cent based on prototype-scale volumes of 1,000 units. The researchers identified an economic break-even threshold at a 12 percent cost increase, noting that volume manufacturing would lower component costs and increase financial viability for fleet operators and private owners. While prototype applications such as Volvo Cars' SmartCell concept and experimental road vehicles exist, mass-production vehicles using reconfigurable battery packs are yet to enter the commercial market.

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Jakson Green Vehicles has selected Dassault Systèmes’ cloud-based 3DEXPERIENCE platform to manage the design and development of its electric vehicles.

The implementation establishes a collaborative engineering framework to maintain digital continuity across the product development lifecycle. By connecting internal teams and external suppliers, the platform automates workflows, standardises component libraries and manages engineering change requests during early-stage product design. Virtual twin capabilities allow the vehicle manufacturer to conduct virtual validation testing to resolve structural and systems design issues prior to physical manufacturing.

Deepak Thakur, CEO, Jakson Green Vehicles, said, "Using Dassault Systèmes’ 3DEXPERIENCE Platform enables us to apply a collaborative approach and re-engineer our product lifecycle from the ground up. Through this transition from legacy environments to a unified digital thread, it enables strong R&D to achieve twin objectives; accelerated time-to-market and mitigated development costs. This partnership is helping us to transform the early-stage innovation and product design processes."

Deepak NG, Managing Director – India, Dassault Systèmes, said, "As India continues its dynamic growth trajectory, virtual twin technology serves as a powerful catalyst for sustainable innovation, empowering industries to rethink how they design, produce and operate."

The software adoption forms part of Jakson Green Vehicles' plan to build urban zero-emission mobility vehicles and infrastructure across India.

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UK-headquartered energy technology company Gelion has entered into a material transfer agreement with a top 15 global automotive original equipment manufacturer to assess its NES cathode platform for future electric vehicle battery applications.

Under the terms of the agreement, Gelion will supply its sulfur-based cathode active material, coated cathodes and liquid electrolyte to the automotive partner. The manufacturer will evaluate the platform in both liquid and solid electrolyte cell configurations, testing compatibility across lithium metal and graphitic anode pathways targeting luxury and mass-market vehicle applications. The technology is designed to serve as a drop-in cathode material capable of integration into existing battery manufacturing lines without re-tooling.

Matt Wood, Chief Executive Officer, Gelion, said, "Our priority markets are commercial & defence drones, EVs and devices. We are honoured to be working with these major global automotive OEMs, and today’s announcement marks further progress towards the adoption of our technology and the generation of commercial revenues via funded programmes and eventually license and royalty revenue in the global EV market, alongside some of the industry’s leading companies."

"The growing engagement from global EV manufacturers reinforces the potential and attractiveness of our NES™ technology. This momentum is also mirrored in our agreements and partnerships across drones and devices, while our work with Tier 1 materials suppliers is advancing the scale-up of our unique, patented battery materials," Wood added.

The agreement expands Gelion’s ongoing industry testing programs with automotive manufacturers, extending the assessment of its sulfur-based cathode platform across liquid and solid battery systems.

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Honda R&D, a subsidiary of Honda Motor Co., has developed underlying technology for a magnetic coupling wireless power transfer road system in partnership with Taisei Corporation and Taisei Rotec Corporation.

The system enables wireless in-motion charging for electric vehicles, including passenger cars and heavy commercial fleets. The partners plan to initiate demonstration testing on public roads starting in FY2027.

The technology integrates high-power-density receiver and transmitter units from Honda with a high-response direct current power supply system from Taisei and road-embedding construction techniques from Taisei Rotec. By supplying power to electric vehicles while in motion, dynamic wireless power transfer reduces the need for stationary charging infrastructure. The initial commercial focus targets logistics and transport operations, where continuous operation offers economic benefits.

The ground assembly embedded in the roadway combines the inverter and coil into a single unit designed to connect via direct current distribution. This design reduces component counts, simplifies wiring and supports installation into existing road surfaces through standard milling methods. The road pavement structures are engineered to withstand continuous traffic loads from vehicles weighing up to 20 tonnes (20,000kg).

Testing conducted at Taisei Group’s T-FIELD facility in Satte verified system stability and structural durability. Starting in late 2026, the companies will build a test roadway at T-FIELD Tamura to evaluate long-term durability under one million wheel-load cycles, measure power transfer efficiency at outputs up to 150 kW and analyse electromagnetic shielding.

The partnership will also join the Tateyama Expressway demonstration project managed by East Nippon Expressway Company starting in 2027.

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