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Metier Technologies, in collaboration with MAHLE Powertrain, will unveil a groundbreaking hydrogen-powered commercial vehicle at the CENEX Expo from September 3-4, 2025, at UTAC Millbrook in Bedfordshire. This innovative project showcases the rapid conversion of existing diesel trucks to 100% hydrogen fuel, offering a practical, zero-emission solution for depot-based fleet operators. By leveraging MAHLE Powertrain’s advanced control technology and Metier’s hydrogen expertise, the partnership demonstrates a viable path to decarbonizing commercial transport without requiring entirely new vehicle platforms.
Key Highlights
- Hydrogen-Powered DAF LF220: Features a 6.7-litre, 6-cylinder engine converted to hydrogen.
- MAHLE’s Flexible ECU Platform: Enables precise hydrogen combustion management.
- Zero-Emission Solution: Offers access to city centers with no emissions.
- Cost-Effective Alternative: Superior total cost of ownership compared to battery electric and fuel cell options.
- Future Plans: Proof-of-concept with fleets by mid-2026, volume deployment by early 2027.
The demonstration vehicle, built on a DAF LF220 platform, integrates a 6.7-litre, 6-cylinder engine adapted for hydrogen combustion. This conversion utilizes MAHLE Powertrain’s Flexible ECU (MFE) platform, which provides sophisticated control for precise engine mapping and calibration. The system ensures optimal performance and safety, critical for hydrogen combustion. MAHLE’s new heavy-duty hydrogen test bed facility in Northampton played a pivotal role in engine mapping and performance optimization, ensuring reliability for the CENEX Expo debut.
James Budgett, Managing Director of Metier Technologies, emphasized the project’s significance: “This initiative proves that existing diesel trucks can be rapidly converted to hydrogen power, offering a commercially viable pathway to zero-emission transport.” The solution supports longer duty cycles and heavier payloads, making it ideal for fleet operators seeking sustainable yet practical alternatives to battery electric or fuel cell vehicles.
MAHLE Powertrain’s expertise in internal combustion engine design enhances the project. Mike Bassett, Engineering Director at MAHLE Powertrain, will present at CENEX Expo, discussing hydrogen internal combustion engine (ICE) design, including combustion CFD and MAHLE Jet Ignition® (MJI) technology. These advancements ensure efficient hydrogen combustion, positioning the partnership as a leader in sustainable transport solutions.
Metier’s approach focuses on regional hydrogen ecosystems, particularly in Scotland and the Southwest, aligning with government commitments to hydrogen production through 2030. The conversion process involves integrating specialized hydrogen injectors, comprehensive engine mapping, and advanced safety systems. This enables a seamless transition to hydrogen power while maintaining vehicle performance.
Looking ahead, Metier plans to conduct proof-of-concept trials with targeted fleets by mid-2026, with volume deployment scheduled for early 2027. The company is also forging partnerships with hydrogen suppliers, fleet operators, and leasing companies to build a comprehensive commercial ecosystem, ensuring scalability and accessibility.
MAHLE Powertrain, a subsidiary of the MAHLE Group, brings extensive expertise in advanced internal combustion engines and electrified powertrain systems. With technical centers in the UK, Germany, and China, and approximately 300 employees, MAHLE Powertrain delivers cost-effective, efficient solutions for global clients. Metier Technologies, a UK-based innovator, specializes in hydrogen powertrain solutions, enabling depot-based fleets to achieve decarbonization without compromising operational capability.
This collaboration marks a significant step toward sustainable commercial transport, offering a scalable, cost-effective solution for fleets aiming to meet zero-emission goals. The CENEX Expo will provide a platform to showcase this transformative technology, highlighting its potential to reshape the future of heavy-duty transport.
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