Latest advances and challenges of hydrogen fuel cells in the automotive, aviation, and racing industries

  • The hydrogen fuel cell is emerging as a sustainable alternative in transportation and racing.
  • Major manufacturers such as Hyundai, Honda, Airbus, and Alpine are investing in hydrogen technology.
  • Challenges remain: limited infrastructure, cost of green hydrogen, and technical challenges.
  • Hydrogen-powered mobility is advancing with real-life models, educational projects, and sports prototypes.

Hydrogen fuel cell in automotive

In recent years, hydrogen fuel cell technology has made significant strides , establishing itself as one of the most promising alternatives for reducing polluting emissions in various sectors. Although its deployment is still limited, several manufacturers, educational projects, and pioneering initiatives are demonstrating the real potential of hydrogen in both transportation and industry.

The use of hydrogen fuel cells is not only generating interest among automotive companies, but is also part of training programs, sporting competitions, and applied research projects. However, the practical viability of this technology remains contingent on several factors, from the production costs of renewable hydrogen to the refueling infrastructure.

The emergence of hydrogen fuel cells in cars and technical education

The government, in collaboration with leading companies, is promoting the teaching of hydrogen fuel cell vehicles among vocational training students. Agreements have been established that allow students to work with engines and vehicles equipped with this technology, and green hydrogen content is being incorporated into advanced automotive vocational training programs. These actions aim to anticipate the challenges of sustainable mobility and train qualified personnel for a future where hydrogen will play a key role in the decarbonization of transport.

In this context, the emphasis is on the fundamental difference between battery electric vehicles and hydrogen fuel cell vehicles . In the latter, electricity is generated from hydrogen stored in tanks, through an electrochemical process that produces only water vapor as a byproduct. Models like the Hyundai Nexo and the Toyota Mirai illustrate the possibilities of this technology, offering ranges comparable to those of conventional cars—around 600-700 km—and very competitive refueling times.

However, these advances are limited by the scarcity of hydrogen stations in markets like Spain and by the high cost of producing renewable hydrogen. Furthermore, most of the hydrogen produced today comes from sources that still generate emissions, highlighting the need to invest in cleaner methods such as electrolysis powered by renewable energy.

Hydrogen fuel cell research

New models and applied projects: from prototypes to production vehicles

The commitment to hydrogen fuel cells is also translating into the arrival of real-world models on the market . The Hyundai Nexo , presented at the Seoul Mobility Show, is a prime example: an SUV capable of traveling over 700 km on a single hydrogen tank, offering a smooth ride and maintaining an eco-friendly profile. Hyundai emphasizes that if hydrogen production were entirely renewable, the entire process would be even cleaner than that of battery-powered electric vehicles, as it avoids the polluting processes associated with mining and the manufacture of large batteries.

Meanwhile, Honda has unveiled its CR-V Fuel Cell , which will compete in the historic Pikes Peak International Hill Climb in Colorado: it will be the first hydrogen-powered SUV to participate in the race. This model combines a second-generation fuel cell, two hydrogen tanks, and a battery that allows for additional electric driving. Honda aims to demonstrate the robustness and efficiency of its technology, highlighting the rapid refueling and the excellent performance of hydrogen in extreme cold. The CR-V e:FCEV, with a combined range of over 400 km and performance typical of a family vehicle, seeks to solidify the viability of hydrogen beyond laboratory prototypes.

On the other hand, Proteus Energy has developed a modular fuel cell solution for the maritime sector , specifically for ports, coastal vessels, and inland waterways. Its systems allow for the addition of modules up to 75 kW to adapt to different needs, minimizing noise and vibration, and offering advantages over traditional batteries, such as long-term fuel storage without losses. This technology is progressing toward certification and is expected to be available to the sector starting in 2026.

Hydrogen fuel cell sports prototype

Hydrogen fuel cells in competition: Le Mans, Pikes Peak, and the future of endurance racing

The world of motorsport is also experimenting with hydrogen as a driver of innovation . A prime example is Alpine's Alpenglow project , which is investigating both hydrogen fuel cells and internal combustion engines, with a view to the upcoming introduction of hydrogen vehicles to the 24 Hours of Le Mans. Alpine has unveiled several prototypes—the Hy4 and Hy6—featuring specially developed engines, pressurized tanks, and optimized bodywork to manage the challenges of hydrogen storage and heat dissipation.

Alpine engineers emphasize that the fuel cell is more efficient at low loads and engine speeds, while the hydrogen internal combustion engine delivers better performance at high loads. In both cases, specific challenges remain: from designing injectors for adequate flow rates to managing material embrittlement and minimizing NOx emissions. In motorsports, liquid hydrogen storage—though challenging due to temperature and pressure—is emerging as a viable option for reducing refueling times compared to the gaseous version in endurance races.

Safety remains a top priority, both due to the risk of ignition and the need for continued development in materials and storage systems. Additionally, manufacturers such as Toyota are collaborating on the development of hybrid prototypes and adapting existing models as the basis for hydrogen-powered vehicles for competition, aiming to replicate the lap times of current hypercars with hybrid aids and rapid refueling.

Hydrogen fuel cell in competition

Current challenges and future prospects for hydrogen in mobility

Despite technological advancements and the commitment of major industrial groups and racing teams, hydrogen fuel cells continue to face considerable barriers to widespread adoption. The main obstacle is the sustainable production of hydrogen at a competitive price and with a low environmental impact. Furthermore, the limited refueling infrastructure—especially in European markets—restricts the vehicles' appeal to the general public.

Specific training at institutes and collaboration with companies in the sector aim to generate knowledge and a skilled workforce, while manufacturers continue to refine fuel cell efficiency and safety and certification regulations. Green hydrogen—obtained through renewable electrolysis—along with new modular solutions and advanced storage, will define the pace of expansion of this technology.

Hydrogen fuel cells remain one of the most promising options for decarbonizing transportation and heavy industry, from private and commercial vehicles to boats and racing prototypes. Available models, ongoing research, and achievements in championships and technology fairs anticipate a future where mobility will diversify, combining batteries, electronic fuels, and, increasingly, the use of hydrogen as a clean and efficient energy source.

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