UK-based consortium unveils 200kW fuel cell system for heavy duty applications
- UK-based consortium unveils 200kW fuel cell system at Cenex Expo 2025
- Fuel cell system designed for heavy-duty vehicle applications
- Directly addresses the key electrification challenges faced by the heavy-duty industry
- APC-backed project set to accelerate the transition to zero-emission heavy-duty transport
Loughborough, UK – 02 September 2025 – The UK-based engineering consortium behind Project ARCHER has unveiled a cutting-edge 200kW fuel cell system designed specifically for heavy-duty vehicles. This next-generation technology marks a significant leap forward in the drive toward zero-emission transport, aligning with the UK’s net zero ambitions.
Backed by funding from the Department for Business and Trade (DBT) through the Advanced Propulsion Centre’s DRIVE35 Demonstrate programme, the consortium – comprising Intelligent Energy (IE), Drive System Design (DSD), and General Engine Management Systems (GEMS) – has developed the latest IE-DRIVE fuel cell system to tackle the most pressing electrification challenges in the truck and bus sectors, including range limitations and refuelling efficiency.
Leading the innovation, Intelligent Energy has integrated its proven core fuel cell stack with a suite of advanced balance-of-plant components, engineered to meet rigorous lifetime and certification standards.
Engineered by DSD, the fuel cell’s multi-input, multi-output converter is a transformative component. As the first converter of its kind, it’s capable of delivering more than 200kW of power, surpassing previous limits of 150kW. This breakthrough enables seamless coupling of multiple fuel cell systems to meet the high-power demands of heavy-duty applications.
To support safe and reliable operation, GEMS has delivered a dedicated ISO 26262-compliant electronic control unit (ECU), providing robust system control in line with automotive safety requirements.
Dr Ashley Kells, Programme Director at Intelligent Energy, commented:
“With simplified vehicle integration, longer life and being certification ready, the IE-DRIVE HD fuel cell is now even better positioned to provide a zero-emission solution for heavy duty applications”
James McGeachie, Head of Electrified Powertrain at DSD, said:
“Our first-of-its-kind converter will give the heavy-duty vehicle industry a welcome power boost to drive it forward on its electrification journey.
“Working closely with GEMS and Intelligent Energy has been key to this success. Each partner has brought sector-leading experience, expertise and innovation to the programme, delivering a world-class fuel cell system solution.”
Peter Bannister, Director at GEMS, added:
“We’re proud to introduce the XCU8 ECU, building on the proven success of our EM80-M controller. Designed for the automotive sector, the XCU8 offers a robust platform for deploying custom control strategies – including Simulink® models – with enhanced functional safety and cybersecurity.”
Intelligent Energy, DSD, and GEMS will be joining forces at the Cenex Expo in Millbrook on 3-4 September, where they’ll showcase their cutting-edge fuel cell system development on the DRIVE35 Demonstrate stand. Attendees will discover how this innovative technology is set to accelerate the sector’s journey toward full electrification.
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About Intelligent Energy Limited
Intelligent Energy is a leader in the development and manufacture of cutting-edge hydrogen fuel cells that overcome the limitations of conventional battery-powered systems.
The privately-owned company, which has 600 patents in place, has been innovating for more than two decades in the automotive, aerospace, power generation, telecoms, materials handling and unmanned aerial vehicle (UAV) sectors.
With its activities spanning key markets in the UK, US, China, South Korea, and Japan, Intelligent Energy has a truly global reach.