AVL is advancing fuel cell technology through a structured, end-to-end development approach that integrates system design, simulation, validation, and industrialization. The company’s engineering framework supports the complete development cycle, from concept definition and stack development to full system integration and production validation, targeting both mobility and stationary energy applications.
A central aspect of AVL’s approach is its engineering methodology, where the fuel cell is not treated as an isolated component but as part of a fully integrated energy system. This includes the coordinated development of the fuel cell stack and balance-of-plant (BoP) subsystems, such as air supply, hydrogen handling, humidification, and thermal management. By optimizing these subsystems together, AVL aims to achieve improved overall system efficiency, durability, and operational stability.
AVL’s development process is strongly supported by model-based design and simulation tools, enabling detailed analysis of system behavior under real-world operating conditions. These tools allow engineers to evaluate key parameters such as efficiency, power output, transient response, and degradation mechanisms, facilitating faster design iterations and more accurate system optimization.
The company also focuses on fuel cell system integration within electrified powertrains, ensuring compatibility with vehicle architectures and energy management strategies. This includes addressing challenges related to load dynamics, system control, and interaction with other drivetrain components, which are critical for achieving reliable performance in mobility applications.
To support validation and industrialization, AVL provides a comprehensive portfolio of testing solutions covering all development stages. These include:
- Component-level testing for cells and stacks
- System-level validation for complete fuel cell systems
- Production-oriented testing, including in-process verification (IPV) and end-of-line (EOL) testing
These test systems are designed to ensure repeatability, accuracy, and scalability, supporting both research and large-scale manufacturing environments.
In addition, AVL offers automation and data management platforms that enable synchronized control of test environments and high-resolution data acquisition. These systems support performance analysis, quality assurance, and traceability, which are essential for meeting industrial standards and accelerating time-to-market.
AVL’s fuel cell development capabilities extend beyond automotive applications to include commercial vehicles, rail, marine, aviation, and stationary energy systems, reflecting the growing role of hydrogen technologies across multiple sectors.
By combining system-level engineering, simulation-driven development, and advanced validation infrastructure, AVL is enabling the development of fuel cell systems that meet the stringent requirements of efficiency, reliability, and scalability—key factors for the broader adoption of hydrogen-based energy solutions.
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About AVL
AVL is a global engineering company specializing in mobility solutions, powertrain development, simulation, and testing technologies. The company works with automotive manufacturers and energy sector partners to develop advanced propulsion systems, including electrified powertrains and fuel cell technologies.
