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The BMW Group is advancing its hydrogen fuel cell technology, preparing for series production of its third-generation drive system. This development enhances the company’s portfolio of zero-emission, high-performance vehicles, leveraging expertise from key European facilities.
Key Highlights
- Third-generation fuel cell system offers a 25% reduction in space, higher power density, and improved efficiency.
- Production set to begin at BMW Group Plant Steyr, incorporating new test rigs and facilities.
- Munich competence center builds prototypes, focusing on system integration and validation.
- Collaboration with Toyota Motor Corporation enables synergies in development for passenger and commercial vehicles.
- Landshut plant manufactures key components like the hydrogen-specific BMW Energy Master.
Evolution of BMW’s Fuel Cell Technology
The BMW Group has progressed through generations of fuel cell systems. The first generation, supplied entirely by the Toyota Motor Corporation, debuted in the BMW 535iA. The second generation appeared in the BMW iX5 Hydrogen pilot fleet, where BMW developed the overall system while sourcing individual cells from Toyota.
For the third generation, the BMW Group and Toyota jointly develop the powertrain, creating synergies for both commercial and passenger applications. This collaboration allows for brand-specific models while sharing core technology.
Improvements in the Third-Generation System
The new system features a compact design, reducing the fuel cell system’s space by approximately 25%. A considerable increase in power density enables this more streamlined construction compared to previous versions.
It also boasts a high degree of integration, allowing seamless incorporation into future vehicle architectures. This supports a technology-open approach, enabling customers to choose from various drive system variants.
Additionally, optimized components and increased efficiency mark significant advancements. Upgrades to parts based on joint Toyota technology, combined with improved operating strategies, result in greater range, higher output, and lower energy consumption over the second generation.
Prototype Development in Munich
At the BMW Group’s competence center for hydrogen in Munich, prototypes of these efficient fuel cell systems are under construction. The process involves an electrochemical reaction where hydrogen from tanks reacts with oxygen from the air, producing electricity to power the electric motor.
The system includes not only the fuel cells but also essential components like the cooling system, hydrogen subsystems, and air subsystems. The compact layout ensures the drivetrain meets BMW’s renowned standards for performance and safety.
Current efforts emphasize development and validation of assembly and testing processes, with focus on industrialization, quality assurance, and long-term scalability. Prototypes aid in refining operating strategies and validating performance at both system and vehicle levels, crucial for series production readiness.
Series Production at Plant Steyr
BMW Group Plant Steyr will handle series production of the fuel cell systems, drawing on decades of expertise in various drive types across the company’s model range. New test rigs, production facilities, and building modifications are underway to integrate and refine this technology.
Klaus von Moltke, Senior Vice President Engine Production at BMW AG and Director of Plant Steyr, highlights the plant’s role in producing innovative drives alongside electric motors and combustion engines, exemplifying the group’s technology-open strategy.
Component Manufacturing at Plant Landshut
BMW Group Plant Landshut serves as a key hub for manufacturing components specific to fuel cell vehicles. Construction of new hardware for the hydrogen-specific BMW Energy Master begins in late May 2026. This unit controls power supply across a 400-800V range and interfaces with the high-voltage battery, supplemented by fuel cell-specific parts.
Prototype production of this Energy Master starts mid-2026 at nearby Plant Dingolfing, where similar units for Neue Klasse models were developed. Landshut will also produce the housing and pressure plate, continuing from the BMW iX5 Hydrogen fleet.
About the BMW Group
With brands including BMW, MINI, Rolls-Royce, and BMW Motorrad, the BMW Group leads as the world’s premium manufacturer of automobiles and motorcycles, offering financial services. Its production network spans over 30 sites worldwide, with sales in more than 140 countries.
In 2024, the group sold over 2.45 million passenger vehicles and more than 210,000 motorcycles, achieving €11.0 billion profit before tax on €142.4 billion revenues. It employed 159,104 people as of December 31, 2024. Sustainability integrates into its strategy across the supply chain, production, and product lifecycle.
For more information, visit www.bmwgroup.com.
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