RESEARCH NEWS
Testing BMW iX5 Hydrogen prototypes
The new BMW iX5 Hydrogen has now reached the next development phase on the road to series production. Current prototypes are undergoing a comprehensive testing programme; in parallel, the third-generation fuel cell system is entering a new assembly phase at the Hydrogen Competence Centre in Munich. Preparations for industrialisation and future series production of the hydrogen fuel cell system are underway at BMW’ s engine facility in Steyr, Austria.
With these steps, the BMW Group is systematically driving the development of its first hydrogen production vehicle. The primary focus is on further validation of the overall system, preparations for industrialisation and the integration of fuel cell technology into a vehicle concept with typical BMW driving dynamics.
Images: @ BMW Group.
Refuelling process for the BMW iX5 Hydrogen( prototype).
Testing of the new BMW iX5 Hydrogen( prototype).
Current testing is focused on validation of the overall system under demanding environmental and operating conditions. The development teams validate the functionality of all components within the integrated vehicle system and optimise the complex control of the systems, even under high loads. The aim is to ensure full performance capabilities of the drive train at all times, while further optimising BMW’ s driving dynamics in the fuel cell electric vehicle.
“ Current testing confirms the coordinated interaction between the fuel cell system, electric motor, high-voltage battery, BMW Hydrogen Flat Storage and Energy Master. The high-voltage battery and the Energy Master, as the high-voltage system’ s central control unit, enable higher recuperation performance and therefore increase overall system efficiency. At the same time, development aims to achieve driving performance on a par with the BMW iX5, including a target acceleration from 0 to 100km / h in less than five seconds,” confirmed BMW.
Prototype assembly
Alongside vehicle testing, the next prototype assembly phase for the third-generation fuel cell system is getting underway at the Hydrogen Competence Centre in Munich. The focus is on finalising and validating the testing methodology, as well as further preparations for industrialisation. The previous prototype phase centred on component buildability and basic qualification of suppliers.
“ The forthcoming process steps establish the necessary conditions for robust and efficient manufacturing processes, making a significant contribution to future series production. Series production of fuel cell systems will take place at BMW Group Plant Steyr in the future,” added BMW.
“ Prototype assembly is about much more than manufacturing individual components. Each phase helps us optimise processes, gain experience and systematically share this knowledge with the teams in Steyr. In this way, we are laying the foundation for the next steps on the road to industrialisation,” confirmed Claudia Stephan, head of Technology Development and Fuel Cell Prototype Assembly at the BMW Group.
Under the“ HyPowerDrive” project, the German Federal Ministry of Transport( BMV) is funding the development of the powertrain and tank system for the BMW iX5 Hydrogen as part of IPCEI Hy2Move. The federal government is providing funding of 191 million euros.
The project is also being( co-) financed by the state of Bavaria with a total of 82 million euros. The funding is administered by Projektträger Jülich( PtJ) and coordinated by NOW GmbH. n
www
. bmwgroup. com / en
£ 95m UKRI funding for material breakthroughs
The Henry Royce Institute has been awarded a further £ 95 million in UK government funding for UK advanced materials research. This boost will extend the research projects that Royce at Cranfield can deliver alongside small businesses, universities and major manufacturers.
“ This funding will extend the work that Cranfield University is already doing to help organisations solve advanced materials problems that would otherwise be out of reach— from hydrogen permeation testing to AI-powered crack detection in turbine coatings. As an Associate Partner of the Henry Royce
Institute, Cranfield University offers businesses and researchers access to its National High- Temperature Surface Engineering Centre,” Cranfield University told ISMR.
For smaller companies, Royce at Cranfield has helped drive new commercial products. Vicki Wilkes, Owner and Director of Darvick Ltd, worked with Royce at Cranfield to develop a hydrogen permeation testing rig.
“ At a time when university research budgets across the UK are under growing strain, shared access to facilities like Royce at Cranfield is increasingly valuable. Equipment access schemes and industrial collaboration projects
( ICPs) allow institutions to carry out advanced materials research without each having to fund costly equipment individually,” added Cranfield University.
Royce at Cranfield has worked with a wide range of UK universities including Loughborough University; the University of Southampton; Bangor University; Coventry University; City University and the University of Manchester. n
www. cranfield. ac. uk
34 | ismr. net | ISMR October 2026