Decarbonization with no compromise

At Hyzon Motors, we currently deploy hydrogen vehicles with up to 150kW fuel cell modules, while preparing for 370kW systems (equivalent to 500 horsepower) to be manufactured at our Rochester facility in New York. Our next-generation 500hp fuel cell systems are well suited to applications such as inter-city rail, mining vehicles, port equipment and marine vessels, as well as long haul and short haul heavy vehicles.

Several major enabling technology breakthroughs help Hyzon drive the decarbonization of heavy-duty applications with the right performance and unit economics:


For decades, fuel cell developers the world over have faced significant challenges in achieving high power-density fuel cell stacks and, more specifically, achieving higher voltage performance at higher current densities (>2.0A/cm2). Several decades of combined research and development experience at Hyzon has helped to overcome these challenges and limitations to produce what are now the world’s highest power single module PEM fuel cell stacks.

Improvements in all fuel cell performance metrics such as gravimetric and volumetric power density have been worked on for over two decades, and achieved through advancements in materials and assemblies. Vertical integration of certain key materials ensures competitive and consistent production.

World’s Highest power-density PEM fuel cell stacks (recently validated by TUV Rheinland)

The core layer in any PEM fuel cell is the Membrane Electrode Assembly (MEA): all electrochemical reactions take place at the MEA level to generate power. It’s also the major cost contributor to the fuel cell, as it contains precious materials.

Hyzon has developed advanced cathode catalysts in-house and uses innovative functionalized ionomers and nanoengineered microporous layers to reduce the Platinum loading in the cathode catalyst layer. It is also developing novel membrane stabilizers to improve membrane lifetime without any trade off in performance or durability. By integrating these new capabilities, tests have shown Hyzon’s MEA outperformed the best-in-class third party catalyst in cell reversal tolerance by a factor of 1.6, highlighting the potential for enhanced freeze start-up capability.

Breakthroughs in high performance, advanced Membrane Electrode Assemblies (MEAs)

Although MEAs can be the center of attention, bipolar plates also play a key role in the fuel cell stack. Bipolar plates direct the flow of reactants to the MEA and help improve the performance  of high power-density fuel cells.

Hyzon’s unique metallic plate development came from the founding team’s deep engineering design and materials innovation knowledge. Surface engineered plates with advanced coating technology, integrated with superior nano materials, offer excellent durability against chemical and electrochemical corrosion. Advancement in producing such thin, high functional metallic bipolar plates integrated with advanced MEAs resulted in Hyzon being capable of manufacturing the world’s highest-powered fuel cell stacks (6kW/l as recorded by third party test authorities).

With Hyzon’s materials and engineering design advancements having aided considerably to produce high power-density fuel cell stacks, the stack operating strategy through system control will complement the materials advancement for the long life of Hyzon’s Hydrogen fuel cell vehicles.

Breakthroughs in bipolar plates - reducing total module size and weight

Hyzon plans to improve throughput manufacturing by eliminating operational bottlenecks, deploying manufacturing automation techniques, reducing equipment downtime and boosting manufacturing safety.

The company has readied large scale roll-to-roll CCM and MEA manufacturing using state-of-the-art facilities and has also committed to implement next generation innovative coating technology which will help to reduce the cost of MEAs.

Artificial Intelligence (AI) will also be applied in certain areas to optimize manufacturing throughput. These factors will aid in producing high power fuel cell stacks at lower costs.

Continuous manufacturing for global scalability

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Rochester, New York, USA usa