The highway to hydrogen mobility
7 minute read
There was a time when the thought of hydrogen-powered vehicles cruising down the highway, running on nothing but water, was confined to comic books and future fantasy movies. When Hyundai started its hydrogen fuel-cell journey 27 years ago, no one in those early research and engineering teams could have imagined the new mobility era they helped set in motion. Cutting-edge FCEVs like the all-new Hyundai NEXO are a part of their legacy.
Driven by the belief in a better future
As the saying goes, 'A journey of a thousand miles begins with one step.' We took ours in 1998 when we decided to develop fuel-cell electric vehicles. At the time, the undertaking was as challenging as it was aspiring. Since we were starting from scratch, we needed a partner to help us along the way – one with knowledge and experience in hydrogen fuel cell technology. After extensive searching, we partnered up with the US company UTC Power, which, together with us, embarked on co-developing a fuel-cell electric vehicle.
The Mercury Project heats things up
Our partnership with UTC Power marked the beginning of the Mercury project, which aimed to establish Hyundai as a significant player in hydrogen fuel cell technology and clean mobility. UTC Power had already established a reputation for innovation by supplying fuel cell systems to NASA. Together, we set out to collaborate on putting hydrogen power on the road.
The project was ambitious in every way, with its own unique set of challenges and demands on the teams. Throughout the Mercury project, Hyundai sent seven engineers to the US to work alongside UTC colleagues. Both teams committed fully to project development. Even while stationed in the US, the Hyundai engineers purposely did not adjust to the local time zone and instead worked night shifts. At the same time, their American colleagues covered the dayshifts, thus allowing the entire team to operate around the clock and accelerate vehicle development.
The first project, Mercury I, was introduced in 2000 and based on the Santa Fe platform. Its international debut and subsequent awards at the ‘2001 Michelin Challenge Bibendum', a sustainable mobility event, showcased Hyundai's commitment to hydrogen-powered mobility. However, that was just the start. Even while the Mercury Project was being carried out, Hyundai engineers were already working towards a new goal, namely the in-house development of hydrogen fuel cell stacks. Its name: The Polaris Project.
Reaching for the stars with
the Polaris Project
Hydrogen fuel cell stacks are an essential component of FCEVs. When Hyundai set out to create its own independently created stacks, it faced a significant challenge – hydrogen fuel cell stacks were notoriously tricky to make. However, the standard was set high, and just like explorers looked up to the North Star for orientation, Hyundai engineers named the project Polaris as their guiding symbol.
You will never create something great in just one attempt. Let young engineers build whatever cars they envision without worrying about the costs. There's no need to produce 100 identical cars to save money. Even if all 100 cars are different, that's fine. — Honorary Chairman Mong-Koo Chung
Hydrogen fuel cells by Hyundai
The Polaris Project aimed to provide Hyundai with hydrogen fuel-cell independence. While this goal was a noble one, the journey was anything but easy. Without any commercial stacks for benchmarking, engineers had to independently procure graphite plates and painstakingly assemble and test each component layer by layer. It was a long and challenging process defined by trial, error, and sheer determination.
In 2004, Hyundai successfully developed its own stack. It was a true milestone and tribute to the skills and tenacity of all those working on the project. The celebratory moment was savored, but the true goal lay. ahead – how to translate this achievement into mass production. The graphite plates used in the vehicle prototype were unsuitable for high-volume manufacturing. To solve this challenge, Hyundai engineers had to reimagine the entire structure – this time employing metallic bipolar plates in a complex 3D design.
It was a demanding time that tested the will of everyone involved, but the team carried on, driven by their belief that this technology could be a game-changer in future mobility. Ultimately, their hard work paid off, and after more than a year of rigorous testing and refinement, they developed a production-ready solution. Completing this goal was a testament to the strength and resilience of a vision. Even outside factors, such as a global financial crisis in the late 2000s and a shift in the industry towards battery electric vehicles, did not stop Hyundai from pushing boundaries in hydrogen mobility. In 2013, we became the first automaker in the world to mass-produce a hydrogen fuel cell vehicle.
In the late 2000s, we toured the US and Europe to promote our hydrogen electric vehicles. During the development of test cars, we faced countless issues like cars not starting or stalling mid-drive, so we were always anxious at these events. But every time, our hydrogen vehicles proudly crossed the finish line. Those experiences led to the hydrogen vehicles we have today. - FCEV Performance Test Team Leader Kang-Sik Jeon
Fuelling the future of clean mobility
We've come a long way since those early days of test trials and graphite bipolar plate stacking. Today, we produce world-class fuel cell vehicles equipped with systems developed in-house. From recognition on the Wards 10 Best Engines & Propulsion Systems list to the world’s first mass-produced hydrogen-powered heavy-duty truck and the All-New NEXO, our hydrogen technology is leading the way as we continue to drive and build a hydrogen ecosystem.
Just as every great building has its architect, I hope that the work I do today becomes something my daughters—and eventually their children—can proudly point to and say, 'My father built that.' I still remember the pride I felt when the NEXO first launched, and my daughters recognized it as the car I had helped create. One day, I hope they’ll see trams, ships, or even aircraft powered by our fuel cells and feel that same pride in their voices. - Application Development Team 1 Leader Nam-Woo Lee
No matter where the journey takes us, we will continue to use all our commitment, curiosity, and expertise to foster innovation and stay true to our philosophy of progress for humanity. We look forward to all the breakthroughs ahead.
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