Honda has developed a hydrogen fuel cell that it says is more efficient and lower-cost than the fuel cell it developed with General Motors and is now deployed in the 2025 Honda CR-V e:FCEV.
Called the “Honda Next Generation Fuel Cell Module,” the new fuel cell has a rated output of 150 kW – almost twice that of the 78 kW generated by the current fuel cell developed with GM.
The output voltage of the fuel-cell stack has a higher range and produces between 450V and 850V. Applications for the new fuel-cell system are still to be announced by Honda, but it could be used for a 100% fuel-cell vehicle or a plug-in hybrid vehicle (PHEV) that uses an 800V battery and the fuel cell as a backup power source.
Despite a great deal of flux in battery-electric vehicle demand and the cadence of demand going forward, with government standards still being discussed and reconsidered in the U.S. and EU countries, automakers continue to invest in various hybrid configurations for personal and commercial vehicles.
The maximum net efficiency of the next-gen fuel cell increased from 56.8% to 59.8%. The volume, says Honda, has been reduced from 557L to 300L. The smaller size and increase in power add up to higher volumetric power density – from 0.14 kW/l to 0.50 kW/l.
This new fuel-cell module, says Honda, has a manufacturing cost one-fifth of the Clarity. Honda says the new fuel-cell module will go into production in 2027, but has not said what vehicles it would go in.
The joint venture between Honda and GM began in 2013, focusing on the co-development of hydrogen fuel-cell systems. This collaboration led to the establishment of Fuel Cell System Mfg. LLC in Brownstown Township, MI, in 2017, with an $85 million investment. The partnership aimed to produce fuel-cell systems for various applications, including the Honda CR-V e:FCEV, a hydrogen-powered version of the crossover produced in Marysville, OH.
Honda has been pursuing hydrogen fuel-cell technology for over three decades. The first foray into FHEVs was the Honda FCX, the world's first zero-emission FCEV certified for everyday use by both the U.S. EPA and the California Air Resources Board.
Building on the FCX’s foundation, Honda unveiled the FCX Clarity in 2008, a hydrogen fuel-cell vehicle that combined hydrogen and oxygen to generate electricity, emitting only water vapor. This model offered a driving range of approximately 240 miles (386 km) and featured a refueling time comparable to conventional gasoline vehicles.
In March 2016, Honda introduced the Clarity FCEV in Japan and later made the car available in select U.S. markets, primarily in California, due to its hydrogen refueling infrastructure.
This model achieved an EPA-rated driving range of 366 miles (589 km), the highest for any zero-emission vehicle at the time, surpassing both fuel-cell and battery-electric vehicles. The Clarity FCEV also boasted a combined fuel economy rating of 67 mpg (3.5 L/100 km) gasoline equivalent (MPGe).The biggest issues facing hydrogen fuel cells are cost and refueling infrastructure. Even if automakers slay the cost issue, as Honda appears to have done, refueling is a huge hurdle for consumers, though less so for commercial vehicles that travel fewer than 300 miles (483 km) daily, and/or drive prescribed distances and routes every day.
The U.S. government, via the Infrastructure Investment and Jobs Act, is investing some $8 billion in hydrogen production hubs. The Trump Admin., though, is trying to halt those investments. Moreover, Trump’s closest advisor on cutting government spending and agencies, Elon Musk, is a long-time opponent of FCEVs in his role as CEO of Tesla Motors.
“While hydrogen cars have not gained significant traction among consumers, hydrogen technology shows promise in other sectors such as aviation and heavy industry,” says Jacob Brouwer, Professor and Chancellor’s Fellow at the University of California, Irvine.
Anup Mankar, lead Analyst at Allied Market Research, highlights the growing interest in hydrogen fuel-cell trucks as an alternative to diesel-powered vehicles. He attributes this to their potential for reducing emissions and increasing fuel efficiency. Mankar also notes that technological advancements, infrastructure development, policy support and market demand are critical factors influencing the adoption of hydrogen fuel-cell trucks.
Trump, however, is not a fan. “My plan will terminate the Green New Deal, which I call the Green New Scam, and rescind all unspent funds under the misnamed Inflation Reduction Act.”
