New technology that could significantly cut the cost of hydrogen fuel cell powertrains has been showcased in the UK.

The demonstrator van uses Printed Circuit Board Fuel Cell (PCBFC) technology from Bramble Energy, designed to reduce the cost and increase the design flexibility of hydrogen fuel cell stacks

Providing a future route for hydrogen fuel cell vans, a demonstrator van was revealed at last week’s Cenex LCV show under a collaboration between Bramble Energy and Mahle Powertrain.

The van uses Printed Circuit Board Fuel Cell (PCBFC) technology from Bramble Energy, designed to reduce the cost and increase the design flexibility of hydrogen fuel cell stacks.

The vehicle, developed under the first phase of the firms’ collaboration, is based on a Renault Kangoo Z.E. electric van with a 5kW Bramble Energy fuel cell integrated into the powertrain and acting as a range extender.

According to the UK government and its recently revealed Hydrogen Strategy, the clean energy source “has the potential to transform the way we power our lives and will be essential to tackling climate change and reaching net zero” – in particular for commercial vehicles.

But there are concerns over the cost of such vehicles, which Bramble Energy is targeting.

While conventional fuel cell stacks rely on stamped plates to hold the various layers, the firm’s approach leverages PCB manufacturing technology, which can be produced cheaply, in virtually any shape using flexible production techniques.

“Hydrogen fuel cells offer an alternative to the heavy batteries and long recharge times that other electric vehicle technologies suffer from, and that makes them particularly relevant to the commercial vehicle sector as it looks to meet net zero CO2 emissions targets,” said Dr. Mike Bassett, Mahle Powertrain’s head of research & advanced engineering.

“Our work with Bramble Energy has demonstrated that their innovative PCBFC technology represents a cost-effective route to the adoption of fuel cell propulsion for commercial vehicles. We’re delighted that visitors were able to see the results for themselves at the Cenex LCV show.”

The project also draws upon Mahle Powertrain’s decade-long experience in powertrain technology integration and its expertise in EV control systems and thermal management. Future development will focus on creating a vehicle with a higher power output and increased overall efficiency.

“Mahle Powertrain’s skills and expertise have enabled us to showcase the benefits of our PCBFC technology in a practical way,” said Dr Tom Mason, Bramble Energy CEO and CTO. “The technical partnership between our two companies will help us accelerate our development and move towards small scale production.”

Bassett agreed: “Our collaboration has been a fascinating journey so far, and we look forward to working closely with Bramble Energy as the next phase of the project begins.”