Hyzon Motors has announced it has developed new onboard hydrogen storage system technology designed to reduce the weight and manufacturing cost of commercial vehicles powered by Hyzon’s hydrogen fuel cells.

According to Hyzon, the new patent-pending onboard hydrogen storage system technology integrates lightweight composite materials with the system’s metal frame. It has the potential to reduce the overall weight of the system by 43%, storage system costs by 52% and the required manufacturing component count by 75%, based on a single-rack system with capacity to store five hydrogen cylinders.

In addition to reducing the weight and costs, the storage system can be configured to hold varying numbers of hydrogen tanks. The smallest version can hold five tanks, and can be extended to seven tanks because of its modular design. A separate version can hold ten tanks, appropriate for trucks driving longer distances.

While these two options are mounted behind the cab, a third storage system allows for an additional two tanks to be mounted to each side of the truck, extending the vehicle’s range without diminishing the size of the trailer.

The development of this technology was a cross-Atlantic collaboration between Hyzon Europe and Hyzon US, with the company planning to produce the new system in both its Rochester, NY, and Groningen, the Netherlands, facilities. The technology will be implemented in Hyzon’s vehicles world-wide.

“Hyzon is committed to continuous innovation in our zero-emission commercial vehicles, down to every detail, enabling our customers to make the switch to hydrogen from diesel without compromise,” said Hyzon CEO Craig Knight.

“After years of research and development alongside our partners, this new storage technology optimises the building cost of our hydrogen fuel cell-powered commercial vehicles, while reducing overall weight and increasing mileage capabilities,” he said.

“This makes Hyzon vehicles an even more attractive alternative to heavy vehicles powered by combustion engines.”

The new technology has already been installed in pilot trucks in Europe and is expected to be deployed across all vehicles beginning in Q4 2021.