AUTOMOTIVE & NEV

The Goal of Zero Emissions

Hydrogen fueling sustainable commercial vehicles
Hydrogen fueling vehicles

The automotive industry is actively working to make passenger vehicles more sustainable. Central to this transformation are innovative companies like cellcentric, specializing in manufacturing fuel cell systems that enhance eco-friendliness of long-haul heavy-duty trucks. Daimler buses produces zero-emission city buses, further contributing to the movement towards greener urban mobility. Both companies aim to produce commercial vehicles with zero emissions and therefore contribute to cleaner transportation.

The fuel cell from cellcentric on the white background

cellcentric: Manufacturing fuel cells as a driver of efficiency

cellcentric develops and manufactures the complete fuel cell system, including all parts of the fuel cell stack, at their site in Esslingen, Germany. They explained the complex process to us.

A hydrogen fuel cell is an electrochemical cell that converts the chemical energy of hydrogen and oxygen into electricity. Imagine a fuel cell system in a heavy-duty truck installed where the combustion engine is today. Hydrogen from a tank reacts with oxygen from the air, separated by a membrane, generating electrical energy to power the electric motor directly and/or to charge a battery. This battery then powers the vehicle via electric motors. The only by-products of this process are water and heat, with no pollutants or greenhouse gases.

How to produce fuel cells

The first step in producing a fuel cell system involves mixing an “ink,” a black emulsification of carbon powder, catalyst, and ionomer. Depending on the recipe, this ink is laminated as cathode or anode on a proton exchange membrane, enabling the electrochemical reaction to generate electricity.

To amplify the electrical power of a fuel cell stack, hundreds of unit cells containing the coated membrane and carbon bipolar plates are assembled in series. The number of cells in one stack depends on several factors, amongst others the desired power output and the geometrical boundary conditions. For cellcentric's 150 kW system, the stack module contains around 500 cells. Assembling hundreds of cells requires the precise measurement of tolerances, as deviations can accumulate during the process. Therefore, cellcentric partners with ZEISS for optical and tactile measurement to ensure high-quality standards in fuel cell production. 

The cell component for fuel cell systems

More on quality assurance for fuel cell systems

Each individual cell component requires a precise inspection to meet stringent demands. This includes coatings, potential surface defects, and weld seams. Find out how the ZEISS portfolio supports these quality processes, ensuring the highest standards.

Till Oberwörder, CEO of Daimler Buses

Daimler Buses: Emission-free city buses

As European cities prepare to switch to emission-free public transport by 2035, Daimler Buses is supporting this transformation with electrically powered city buses. We talked to Till Oberwörder, CEO of Daimler Buses.

What progress has your company made in electrification so far?

We are in the midst of the transformation that we, as a manufacturer, are actively driving forward together with our customers. We are building on both battery-electric and hydrogen-based technologies and have a clear e-roadmap. City buses are already well advanced in terms of electrification and are in daily use in many cities. In 2026, our first electrically powered inter-city bus will follow, which will also electrify connections between cities and rural areas – and electric coaches will follow by the end of the decade.

Where do you see the biggest challenge in the transformation of your industry?

For bus operators to be able to operate electrified fleets, a functioning and reliable charging and hydrogen tank infrastructure is required – across the board. Charging infrastructure is the pivotal point for the ramp-up of electromobility.

How are you approaching this challenge?

We are relying on an intensive dialog with policy makers, energy suppliers and our customers – only if all parties involved are fully committed to driving electrification forward will it work in the long term and across the board, i.e. beyond the highways. Moreover, our own strategic approach goes far beyond the vehicle itself. We not only offer our customers electrified buses, but also complete solutions for operating electric fleets. For this purpose, we established a new subsidiary, Daimler Buses Solutions GmbH, in 2023. On request, bus operators can obtain a complete e-system from a single source: From individually configured electric buses to complete charging infrastructure for the depot, including construction measures, electrical installations, chargers, battery storage and other digital services.

ZEISS solutions for hydrogen fuel cells

From water to power

As the automotive industry strives for zero emissions, hydrogen fuel cells emerge as a key technology. But the journey from hydrogen production to powering vehicles hinges on the quality of bipolar plates. Discover how ZEISS solutions support the advancement of clean technologies.