Toyota Motor Corporation has developed its third-generation fuel cell system, designed to meet the needs of the commercial sector with the same durability as conventional diesel-powered engines.

The new system features improvements in performance, including fuel and a significant reduction in costs compared to the previous version. In addition to passenger vehicles, the third-gen FC system will be expanded for use in heavy-duty commercial vehicles and is planned for debut in markets such as Japan, Europe, North America, and China from 2026 onwards.

The third-gen FC system will be unveiled for the first time on February 19 at the H2 & FC Expo (International Hydrogen & Fuel Cell Expo) in Tokyo, Japan.

Toyota says it considers hydrogen an important fuel in pursuit of carbon neutrality. In 2014, the company launched the Mirai fuel cell electric vehicle (FCEV) and has since sold 28,000 units across 30 countries and territories. Additionally, since 2019, Toyota has been supplying FC systems for use in other applications, such as buses, railroads and stationary power generators, and has supplied more than 2,700 units to more than 100 customers globally.

In Japan, Toyota works with many partners, particularly in the Tokyo and Fukushima prefectures, to implement these systems in the commercial sector and help create a hydrogen society. Toyota says the new third-gen FC system was developed based on customer feedback and insights from proof-of-concepts and demonstration tests over the past several years.

For passenger vehicles, the improved fuel efficiency provides greater cruising range for further peace of mind. For heavy-duty commercial vehicles, the new FC system offers a level of durability comparable to diesel engines and high power. In addition, by designing the system to be more compact, it can be more easily integrated into various commercial vehicles.

Toyota states that it is up to two times more durable than the preceding generation and 1.2 times more fuel efficient. The third-gen FC system can also be installed in a variety of commercial vehicles, passenger cars, and general-purpose applications, such as stationary generators, rail, and ships.

BorgWarner has secured four new projects with three major Chinese domestic brands. The projects include the supply of 400V high-voltage hairpin (HVH) motors to a Chinese vehicle supplier for their hybrid rear-drive platform, with production planned to commence in August 2025.

BorgWarner will also provide motors for a top Chinese domestic OEM’s 150kW pure electric platform, scheduled for mass production in March 2026. The company will also supply electric motors for the next-generation vehicles of another major Chinese domestic OEM, covering both range-extended and plug-in hybrid models, with production expected to begin in August and October 2025.

“We are pleased to extend our success in China with several new electric motor business wins for a variety of hybrid and electric applications,” said Dr Stefan Demmerle, president and general manager of BorgWarner PowerDrive Systems.

“We are dedicated to continuously innovating our technology and improving our manufacturing processes to deliver high-quality products and services to meet the evolving needs of new energy vehicle customers.”

To meet the growing demand in China’s new energy vehicle market, BorgWarner has introduced a new e-motor technology called Ultra-Short High-Voltage Hairpin (S-HVH). This technology uses an optimized manufacturing processes to produce very short end turn lengths which reduce overall length of the motor. The S-HVH eMotor reduces end size by over 5mm compared to traditional HVH winding, while also lowering axial volume, increasing power density and reducing copper use for improved efficiency and cost savings.

This makes the technology compatible with existing production lines, enabling easy factory upgrades. Versatile and adaptable, it supports a wide range of new energy vehicle models and is suitable for both 400V and 800V platforms.

Ricardo has signed a deal to supply bespoke, manual transmissions to Singer’s operations in the USA and UK. The transmissions in question will be exclusive to Singer and will initially be available to owners who request Singer’s Classic Turbo or DLS Turbo restoration for their 964 Porsche 911.

Singer arrived on the automotive scene with its Classic services in 2009, and has since developed restoration services allowing owners to personalize both naturally aspirated and turbocharged cars.

Ricardo’s design team will ensure that the transmissions meets the high-performance needs of Singer’s clients. The focus is on delivering an H-pattern transmission able to accommodate the additional demands that a turbocharged car places on the drivetrain. Designed to seamlessly integrate into the existing chassis, the transmission will enable smooth, engaging gear shift operations despite the increased torque and power from forced induction.

The transmissions will be manufactured and tested at Ricardo’s state-of-the-art Midlands Technical Centre in Leamington Spa in the UK.

Richard Guest, managing director of Performance Products at Ricardo, said, “We are delighted to be working on this significant multi-year project, supplying Singer in the UK and US with a series of transmissions that will support the growth of their customer base.

“The passion and detail that they demonstrate through these vehicles is a great match with the drivetrain expertise that Ricardo can provide. We look forward to supporting the Singer team on this project and building on our existing relationship.”

Mazen Fawaz, chief strategy officer, Singer Group, noted, “Our approach is always based around execution without compromise. This leads us to seek out and collaborate with the best in the world. An exceptional, truly engaging, manual transmission is an essential part of the remarkable sports cars that we pursue, on behalf of some of the most discerning drivers in the world. We look forward to continuing this pursuit in collaboration with Ricardo.”

KGM has signed a technical cooperation agreement with Phinia Delphi France to jointly develop hydrogen engines. The collaboration was confirmed last month at KGM’s R+D center in Pyeongtaek, South Korea.

KGM is currently participating in the MOTIE national project in Korea. The project refers to the South Korean Ministry of Trade, Industry and Energy (MOTIE) initiatives focused on promoting low-carbon technologies and practices, to reduce greenhouse gas emissions and transition toward a carbon-neutral economy within the country.

This national project aims to develop a 2-liter diesel-based hydrogen engine and vehicle that meets NOx emission regulations and achieves a driving range of over 500km, making it suitable for both industrial and vehicular applications.

Phinia is a global leader in supplying key hydrogen and diesel engine components, including engine management systems (EMS), injectors, and pumps. KGM will integrate its in-house diesel engine technology with Phinia’s Fuel Injection Equipment (FIE) system and ECU technology to accelerate the project.

The development roadmap consists of designing a multi-purpose engine and vehicle, performance development, and the base design of an Extended Range Electric Vehicle (EREV), including further research and development.

A KGM representative said, “Eco-friendly hydrogen engines are a crucial next-generation powertrain technology. The hydrogen engine developed through this collaboration will be applicable not only to vehicles but also to construction and industrial machinery.”

The company has also confirmed the launch of plug-in hybrid technologies, within its existing range, throughout 2025.

Mahle Powertrain has entered the testing phase of a project that will promote the use of hydrogen fuel in existing heavy-duty truck engines. Dubbed Project Cavendish, it is a £9.8m (US$12.2m) government-funded program facilitated by the Advanced Propulsion Centre UK (APC).

The project will deliver solutions and a clear upgrade path to enable hydrogen combustion using current platforms and infrastructure. It involves Mahle Powertrain’s flexible testing facility in Northampton, combined with the company’s experience with alternative fuels such as hydrogen and methanol.

“Hydrogen combustion engines (H2 ICE) are well suited to heavy-duty, long-distance applications that are hard to electrify,” said Jonathan Hall, Mahle Powertrain’s head of research and advanced engineering. “Its use allows industry to take advantage of years of development and investment as a means to accelerate the transition toward net zero.”

The EU’s recently revised CO2 standards for heavy-duty vehicles require a 45% reduction in CO2 emissions by 2030, rising to 65% by 2035 and 90% by 2040. In response to this legislation, the UK government has committed £8.3bn (US$10.3bn) for Great British Energy – a new, publicly owned, clean-energy company – to invest in the hydrogen industry and up to £21.7bn (US$27bn) for large-scale infrastructure projects.

Project Cavendish draws on the experience of several partners including Phinia, BorgWarner, Cambustion, Hartridge and Mahle Powertrain to develop novel fuel-injection systems and supporting turbocharging parts that can be ready for high-volume production in time to meet legislation.

Mahle’s recently expanded Northampton facility has the capacity to hold two tube trailers on-site, with rapid switch-over between them to ensure a near-continuous supply of hydrogen. Upgraded engine dynamometers with a 900kW/4,000Nm nominal capacity can support key heavy-duty demands, while in-house-designed control systems and software ensure safety.

Magna has been a strategic partner to Mercedes-Benz for decades, a partnership that has seen the production of more than 500,000 G-Wagons at Magna’s Graz, Austria, facility since 1979 and which now sees Magna supplying the eDS Duo, an e-drive system for all-electric G-Wagon models.

“Strong partnerships with our customers are essential for driving innovation and advancing the automotive industry,” said Eric Wilds, Magna chief strategy and commercial officer. “Our continued partnership with Mercedes-Benz exemplifies how working together can lead to groundbreaking solutions and mutual success.”

In 2024, Magna began production of the eDS Duo, an e-drive system with exceptional traction properties, at its Lannach, Austria, facility, marking a new chapter in the partnership. The all-new electric model of the iconic off-roader is now equipped with this advanced electric drive system for leading performance and efficiency.

“Having supplied three generations of transfer cases for Mercedes-Benz’s G-Wagon, Magna is honored to now equip this legendary vehicle with its first generation of electric units,” said Diba Ilunga, president of Magna Powertrain. “The eDS Duo demonstrates Magna’s flexible approach to delivering powertrain solutions, transitioning seamlessly from internal combustion engines to battery electric vehicles.”

The eDS Duo is a 2-speed, dual e-motor drive covering a power range of up to 240kW. It offers leading traction and off-road capabilities, including a unique wheel-individual propulsion system that enables features like the ‘G-Turn’, enabling the vehicle to rotate 360° in place. With optimized efficiency and advanced silicon carbide and decoupling technology, the eDS Duo delivers “exceptional performance while maintaining high efficiency”, according to Magna.

Phinia has announced two partnerships with sports car and motor racing company Alpine – it will support Alpine in the development of its Alpenglow hydrogen-powered prototype and has renewed and expanded its multi-year partnership with BWT Alpine Formula 1 Team.

Phinia powers Alpenglow’s hydrogen racing future

Phinia has supplied its DI-CHG direct hydrogen injectors and associated driver technology, which will help to “power Alpine’s vision for a zero-emission future with the Alpenglow”, the company said.

The DI-CHG injectors are designed for high-performance internal combustion engines using hydrogen, offering features such as precise fuel delivery, multiple injection capabilities and compatibility with both compressed natural gases (CNG) and hydrogen gases. These injectors are an essential part of Alpenglow’s hydrogen combustion system.

The six-cylinder Alpenglow Hy6 debuted at last year’s Paris Motor Show after the four-cylinder version was showcased at the Total Energies 6 Hours of Spa-Francorchamps in May 2024.

On the collaboration, Pierre-Jean Tardy, chief engineer, hydrogen, at Alpine Racing, said, “We are thrilled to have Phinia as our technical partner on this exciting journey into hydrogen mobility. Their expertise in fuel systems and advanced injector technology is critical to making Alpenglow a reality, and together we are pushing the boundaries of what’s possible in motorsport.”

Delphi renews partnership with BWT Alpine Formula 1 Team

Phinia, under its leading aftermarket brand, Delphi, is set to strengthen its existing three-year partnership with BWT Alpine Formula 1 Team. Having previously been present on the cars at selected race events, the Delphi logo will now feature on the team’s single-seaters and associated commercial assets, maintaining a strong presence throughout the F1 calendar.

“We are excited to continue our partnership with Alpine Racing and BWT Alpine Formula 1 Team,” said Neil Fryer, vice president and general manager of Phinia’s global aftermarket business.

“The close collaboration between Phinia and Alpine Racing reflects Delphi’s position as a high-performing technical leader which, through this partnership, is helping to develop more sustainable combustion technologies in high-performance vehicles.”

Continental has developed a line for cooling in commercial vehicle hydrogen powertrains that reduces the penetration of ions into the media circuit, promising to increase the service life of vehicle components in hydrogen systems.

The material experts from ContiTech seem to have solved a big challenge in the industrialization of the hydrogen drive system. If ions from the line material enter the cooling circuit, this can lead to degradation, which in turn reduces efficiency and increases the risk of a short circuit or leakage currents in the fuel cell.

To eliminate this, Continental is using a mixture of synthetic rubber for cooling in the hydrogen circuit. It is a special mixture based on high-performance EPDM (ethylene-propylene diene rubber) that offers the necessary high resistance against the unwanted leaching of ions.

Compared to the use of battery-generated drive energy, engineers in the vehicle industry face a large number of challenges when it comes to hydrogen. The extremely low density of hydrogen atoms also presents new hurdles. Harald Kreidner, head of research and development at ContiTech’s OESL business, added, “Permeation resistance, anti-static and high pressure are challenging requirements. We are combining our material expertise so we can tailor elastomers, thermoplastics and metals for use in hydrogen powertrains.” As the smallest molecule with the lowest density, hydrogen is so light and volatile that conventional lines do not form a barrier.

Continental is addressing this with a hose construction featuring a thermoplastic barrier layer which prevents the hydrogen atoms from being released despite their low density. This guarantees the safe operation of a vehicle as it minimizes the probability of a flammable hydrogen-air mixture occurring in the hydrogen carrying line. This also increases range as fuel loss is reduced.

“In the OESL business area, we have decades of experience as a system partner for media circuits and engine mounts in combustion technology. Our customers benefit hugely from this experience and the joint development of lines, splices and mounting components for hydrogen and battery drive systems in commercial vehicles,” said Mark Klein-Hietpas, director, CV sales, OESL business area at Continental.

Continental will be exhibiting at Tire Technology Expo 2025 in Hannover, Germany, March 4, 5 & 6 (Booth 4008). Register for your FREE entry pass here.

BorgWarner is supporting SAIC Maxus by supplying two types of its locally developed and manufactured transfer cases: an on-demand transfer case with mechanical locking and a high-torque part-time transfer case. Mass production is expected to begin in 2026.

“BorgWarner’s relationship with SAIC Maxus spans more than a decade. Our transfer case technology not only supports SAIC Maxus in strengthening its position in the Chinese market but also empowers its expansion into overseas markets,” said Isabelle McKenzie, vice president of BorgWarner and president and general manager of Drivetrain and Morse Systems.

BorgWarner’s advanced transfer case products feature the company’s HY-VO driveline chain, improving efficiency under high-speed operating conditions. The transfer cases can support two-wheel-drive high-range (2H) and auto modes, delivering better fuel efficiency on paved roads than a conventional full-time four-wheel-drive (4WD) system.

For vehicles with on-demand 4WD, these transfer cases provide enhanced safety, handling and driveeability; the mechanical locking mode delivers off-road performance, climbing ability and recovery capability for all terrains.

Featuring a design that integrates on-demand and part-time 4WD systems, coupled with proven reliability and market validation, BorgWarner’s transfer cases promise to deliver exceptional performance and provide robust support for SAIC Maxus models.

Johnson Matthey (JM) and Bosch have agreed to partner on the development of zero-emission hydrogen technology. They intend to develop and produce catalyst-coated membranes (CCM) for use in fuel cell stacks.

Hydrogen fuel cells are electrochemical devices that combine hydrogen and oxygen to generate electricity. As pure water is the only byproduct, fuel cell electric vehicles are a clean option.

JM’s high-performance CCMs will be used in Bosch’s integrated, compact and scalable fuel cell power module for commercial vehicles, designed for longer distances.

JM Hydrogen Technologies chief executive, Anish Taneja, and Bosch Mobility’s executive vice president of Engineering Power Solutions, Beate Grota, marked the agreement at Bosch’s fuel cell center in Stuttgart-Feuerbach, Germany.

Taneja commented, “JM is thrilled to be joining forces, exploring and developing future possibilities to accelerate cleaner mobility and energy generation.”

Grota added, “The fuel cell technology for mobile applications is technologically ready for widespread use. Our partnership aims to further increase the performance and efficiency of the fuel cell stacks.”