Hyzon Motors, a high-power H₂ fuel cell technology developer and global supplier of zero-emission heavy-duty fuel cell electric vehicles (FCEVs), announced the successful completion and factory acceptance testing of the first nine single-stack 200-kW fuel cell system (FCS) B-samples at its production and innovation center in Bolingbrook, Illinois. By achieving this milestone, Hyzon remains on track to declare start of production and commercialization of its innovative FCS in 2024. 

The successful completion of testing of Hyzon’s nine 200kW FCS B-samples in the first half of 2023 demonstrates consistent progress toward commercial production. This achievement follows the commissioning of Hyzon’s proprietary, automated roll-to-roll membrane electrode assembly (MEA) production line including in-line inspection and the installation of its single cell and fully automated fuel cell stack manufacturing lines. Progression of the 200-kW FCS B-samples validates the design, equipment, and operating procedures, which are all critical to the final tooling and production of C-samples and the eventual commercialization of the FCS.  Additionally, we believe it shows growth in the company’s prototype assembly rate, with six of the B-samples produced and tested in Q2 2023, an increase from three in Q1 2023.

Hyzon is positioning to increase its FCS manufacturing rate with the installation of additional full and semi-automation equipment in the assembly and inspection processes, which is already underway. We also expect the continued standardization of design around the 200-kW FCS powertrain components will expedite production and the Company expects the remaining 16 B-samples to be complete and the production of C-samples to begin in the second half of 2023.

“Our goal is to accelerate the clean energy transition by providing H₂ fuel cells to power zero-emission mobility,” said Parker Meeks, Hyzon’s Chief Executive Officer. “In our view, this milestone reflects Hyzon’s years of leadership in developing H₂ fuel cell technology, and this important step toward full-scale 200-kW FCS production demonstrates exciting progress toward the commercialization of our single stack design.”

Hyzon’s single-stack 200-kW FCS provides significant advantages relative to current industry standards. While most FCEV suppliers achieve 200k-W output by coupling two ~110-kW FCSs, Hyzon has developed proprietary material, design, and equipment engineering enabling 200kW output from a single stack. This breakthrough is expected to result in the following improvements:

• 20% increase in miles per kilogram of H₂ vs the 120-kW FCS – greatly improving the truck total cost ownership (TCO)
• 30% smaller volume and weight
• 25% lower cost
• Materially less maintenance than two 100-kW long-range fuel cell systems due to the relative simplicity of design.

The demand environment for H₂ fuel cell systems is robust, with approximately 68-MM diesel-powered vehicles globally emitting roughly 11 Btpy of carbon. Further, the U.S. government has made significant commitments to the industry, including the $7 B committed through the Department of Energy’s H₂ Hub Program, as well as several programs contained in the Inflation Reduction Act, such as:

• $60 MM for the Diesel Emission Reduction Act program
• $2 B for the Domestic Manufacturing Conversion Grant program
• $3 B for the Advanced Technology Vehicle Manufacturing program
• A long-term extension of the Advanced Manufacturing Production Credit
• $2.25 B to reduce air pollution at ports through deploying zero-emission technology.