Hyzon Launches Full-Scale Production of Single-Stack 200kW Fuel Cell System

Hyzon, a U.S.-based manufacturer and developer of hydrogen fuel cell systems, has announced the Start of Production (SOP) of its groundbreaking single-stack 200kW Fuel Cell System (FCS). This advancement enables Hyzon to produce standardized fuel cell systems at scale for commercial use, thereby accelerating the decarbonization of heavy-duty industries.

With the SOP announcement, Hyzon has met all necessary conditions for full-scale manufacturing, marking the transition from prototype development to the production of standardized units. This fully integrated manufacturing approach is central to Hyzon’s strategy, enhancing rapid product development, customer responsiveness, and overall power output. Unlike many competitors who source individual fuel cells or components, Hyzon manages the design and production of its proprietary Membrane Electrode Assembly (MEA), the core component of any fuel cell and FCS.

The production line for the single-stack 200kW FCS is located in Bolingbrook, Illinois, where multiple workstations have been strategically designed to optimize production flow. Bolingbrook is now home to one of the largest fully integrated fuel cell production facilities in the United States.

“Our transition to full-scale manufacturing is a major milestone, as it allows us to move from building prototypes to producing standardized units at volume—from MEA to complete FCS,” said Dr. Christian Mohrdieck, Hyzon’s Chief Technology Officer. “With the in-house design, development, and now manufacturing of our proprietary 7-layer MEA, we are advancing cutting-edge technology that is crucial to delivering high-performance, zero-emission solutions.”

Dr. Bappa Banerjee, Hyzon’s Chief Operating Officer, highlighted the significance of the SOP declaration, stating it validates the company’s capacity to produce 700 fuel cell systems annually across a three-shift operation.

Hyzon has also successfully passed the ISO 9001 audit in September 2024 and anticipates formal ISO 9001 certification for its fuel cell manufacturing and design/R&D activities in the fourth quarter of 2024.

The launch of the 200kW FCS comes shortly after the company announced the SOP for its Class 8 200kW Fuel Cell Electric Truck (FCET) last month, further expanding its footprint in the hydrogen fuel cell market.