The heavy-duty transport industry has long wrestled with one major problem: how to electrify trucks and buses without sacrificing range, performance, or refueling convenience. Batteries alone often fall short. Hydrogen fuel cells, however, are emerging as a compelling answer. And now, a UK-based consortium has now taken a big step in that direction.
At the Cenex Expo 2025 in Millbrook, Intelligent Energy (IE), Drive System Design (DSD), and General Engine Management Systems (GEMS) introduced a new 200kW fuel cell system designed specifically for heavy-duty applications. Known as the IE-DRIVE HD, the platform is backed by the UK’s Department for Business and Trade through the Advanced Propulsion Centre’s DRIVE35 Demonstrate program.
The system represents a leap forward from earlier fuel cell technologies, which typically maxed out around 150kW. By surpassing that limit, the IE-DRIVE opens the door for trucks, buses, and other large vehicles to rely on fuel cells for zero-emission power without compromising on the performance these industries demand.
At the heart of the innovation is Intelligent Energy’s core fuel cell stack, which has been integrated with advanced balance-of-plant components to meet demanding lifetime and certification standards. DSD contributed the breakthrough converter, a multi-input, multi-output design that enables seamless coupling of multiple fuel cell systems to hit power targets above 200kW. It’s the first of its kind in the sector.
To keep everything safe and reliable, GEMS delivered the XCU8 electronic control unit, fully compliant with ISO 26262. Building on the company’s proven EM80-M platform, the ECU provides robust control, functional safety, and modern cybersecurity measures—crucial for real-world deployment in automotive environments.
Consortium leaders say the project directly addresses the electrification roadblocks facing heavy-duty transport. Longer service life, simpler integration into vehicle platforms, and certification readiness make the IE-DRIVE an attractive proposition for manufacturers seeking a viable zero-emission solution.
The unveiling at Cenex Expo is more than a product launch. It’s a signal that fuel cell technology is rapidly maturing beyond pilot projects and into systems capable of powering large fleets. Hydrogen infrastructure still must catch up, but systems like this show the technology is ready when the market is.
