September 2025 – A groundbreaking 200kW+ fuel cell system has been launched by propulsion systems specialist Drive System Design (DSD), hydrogen fuel cell manufacturer Intelligent Energy, and UK-based electronics engineering specialist General Engine Management Systems (GEMS).  The industry-first innovation, completed under Project ARCHER, is set to accelerate the transition to zero-emission heavy-duty transport.

Part funded by the Advanced Propulsion Centre, the new IE-DRIVE HD fuel cell system directly addresses the key electrification challenges facing the truck and bus markets, including range and refuelling times. 

Engineered by DSD, the fuel cell’s multi-input, multi-output converter is a transformative component. As the first converter of its kind, it’s capable of delivering 300kW of power, surpassing previous limits of 150kW. This breakthrough intelligently couples multiple fuel cell systems, unlocking the high-power outputs required for heavy-duty vehicle applications. 

Unlike conventional systems that require individual converters for each fuel cell stack, DSD’s solution streamlines the process with a single, integrated converter. It eliminates the need for multiple high- and low-voltage supplies, reducing complexity, cost, and packaging size. 

Intelligent Energy has led the development of the IE-DRIVE HD fuel cell system, integrating its proven core stack with advanced balance of plant components engineered to meet demanding lifetime and certification standards. To support safe and reliable operation, GEMS has delivered a dedicated ISO 26262-compliant electronic control unit (ECU), ensuring robust system control in line with automotive safety requirements. 

The fuel cell system’s ECU is certification-ready with a proven design methodology. It delivers improved operational life through intelligent fuel cell health monitoring using embedded EIS techniques. 

The companies worked collaboratively, sharing IT systems, communication platforms and data tools to accelerate progress. Crucially, the team agreed clear requirements, avoiding redesign delays and ensuring the project was delivered at speed with maximum impact.

James McGeachie, Head of Electrified Powertrain at DSD, said: “Our first-of-its-kind converter will give the heavy-duty vehicle industry a welcome power boost to drive it forward on its electrification journey. 

“Working closely with GEMS and Intelligent Energy has been key to this success. Each partner has brought sector-leading experience, expertise and innovation to the programme, delivering a world-class fuel cell system solution.”

Dr Ashley Kells, Programme Director at Intelligent Energy, said: “With simplified vehicle integration, a longer life and being certification ready, the IE DRIVE HD fuel cell is now even better positioned to provide a zero emissions solution for heavy duty applications.”

Peter Bannister, Director at GEMS, said: “The XCU8 ECU builds on the proven success of our EM80-M controller. Designed for the automotive sector, the XCU8 offers a robust platform for deploying custom control strategies, including Simulink® models, with enhanced functional safety and cybersecurity.” 

DSD, Intelligent Energy and GEMS will be at Cenex Expo in Millbrook on 3rd and 4th September, at the Advanced Propulsion Centre UK Stand (C3-702). They will be showcasing the new fuel cell system at the and how it will pave the path for electrification for the sector.