Hydrogen fuel cell – integrated system solutions from Hexagon Purus

One of the main challanges is the safe and efficient storage of hydrogen. As the gas has an extremely low density, it must be compressed for mobile use. This requires high-strength yet lightweight tank systems that combine safety, weight efficiency, and practicality.
In addition, the distribution of hydrogen poses a considerable infrastructural challenge. For example, green hydrogen is usually produced decentrally – by electrolysis using renewable electricity. In the absence of a nationwide pipeline system, transportation to the filling station or industrial consumer is associated with considerable logistical effort and high costs.
Last but not least, the integration of hydrogen technologies in commercial vehicles requires a high degree of system expertise. The combination of high-pressure cylinders, control technology, valves, safety architecture, and fuel cell must be precisely coordinated and embedded in the vehicle concept. This complexity poses major challenges for many manufacturers and calls for standardized, ready-to-install solutions that guarantee safety, reliability, and performance.

One of the key technical challenges in the use of hydrogen in mobile applications – especially in heavy goods transport – is the safe, space-saving, and lightweight storage of the gaseous energy carrier. Conventional steel pressure vessels are unsuitable for this due to their high weight. The solution lies in highly developed storage systems such as those developed and mass-produced by Hexagon Purus.
At the heart of this storage technology are hydrogen high-pressure Type 4 cylinders. They consist of an inner plastic liner, which ensures gas tightness, and an outer wrap of high-strength carbon fiber composite material, which provides structural stability at high operating pressures. Hexagon Purus' hydrogen high-pressure Type 4 cylinders are available as complete storage systems—including valves, pressure regulation, and safety architecture – and are specially designed for series production and retrofitting.
Especially in the commercial vehicle sector, where range and payload are key economic factors, this weight saving is a critical success factor. This is because the full potential of the fuel cell can only be exploited with a lightweight yet powerful hydrogen storage system.

Learn more →

Hexagon Purus combines hydrogen storage, battery systems, and comprehensive vehicle integration into complete turnkey systems that are optimally tailored to the requirements of OEMs, fleet operators, and conversion projects.
The high-voltage battery packs developed by Hexagon Purus are among the most powerful on the market. Their market-leading gravimetric and volumetric energy density is based on a patented, particularly space-saving module design. The battery packs are routed as a continuous unit around the side members of the vehicle frame. This maximizes the usable area on the chassis, facilitates service access, and enables particularly compact vehicle concepts.
Complementing the Power Module and the Accessory Module, a fully integrated system solution is created that covers all requirements for energy supply, power electronics, and auxiliary consumers.
As a system partner, Hexagon Purus undertakes the complete integration of the drive technologies into the vehicle – including mechanics, electrics, software, and safety validation. This holistic development and implementation service makes zero-emission commercial vehicles economically attractive, technologically robust, and quickly ready for the market.

Learn more →