Researchers at the University of New South Wales (UNSW) have developed a redesigned hydrogen fuel cell that could accelerate the commercial viability of hydrogen-powered transport, particularly for heavy vehicles and aviation where battery-electric technology can be challenging to deploy.
The breakthrough addresses a long-standing technical issue that has limited the performance and reliability of hydrogen fuel cells — the build-up of water inside the system that restricts airflow and reduces efficiency.
A multidisciplinary team led by Dr Quentin Meyer and Professor Chuan Zhao from the UNSW School of Chemistry has introduced a new internal structure that allows excess water and gas to escape before they accumulate. The research was published in the journal Applied Catalysis B: Environment and Energy.
“Hydrogen fuel cells generate clean electricity with water as the only byproduct,” said Dr Meyer, a Senior Research Fellow in Professor Zhao’s team.
In theory, hydrogen fuel cells could provide a low-emissions energy source for industries that are difficult to electrify using batteries alone. However, translating that promise into reliable and cost-effective real-world applications has proven difficult.
A simple design change with a significant impact
The UNSW team’s solution focuses on the architecture of the fuel cell itself. Using high-precision micro-scale engineering, they introduced microscopic channels — about 100 micrometres wide — into the internal structure of the cell.
These channels act as “lateral bypasses”, allowing water to exit the system before it interferes with the chemical reaction that generates electricity.
“There’s usually no way to remove water,” said Dr Meyer.
“But these lateral bypasses act as escape routes, meaning water no longer accumulates and stops the cell working.”
According to the research team, the redesigned fuel cell achieved up to 75 per cent more power than conventional designs, while requiring only minor structural changes. The approach also reduces reliance on costly materials such as platinum and can help make fuel cell systems lighter and less complex.
That combination of improved performance and reduced cost is considered essential for hydrogen technology to compete with diesel and battery-electric alternatives in commercial transport.
Why this matters for heavy transport and aviation
Hydrogen fuel cells have been widely discussed as a future energy solution for long-distance freight, aviation and other high-utilisation applications where energy density, payload and refuelling time are critical operational factors.
Battery-electric vehicles are already delivering strong results in light and medium-duty fleets, particularly where predictable routes and depot charging are available. However, heavier vehicles operating over long distances or carrying significant payloads can face constraints around charging infrastructure, downtime and vehicle weight.
The UNSW researchers believe their redesigned fuel cell could help address these limitations by improving efficiency and reducing system complexity.
“I believe aeroplanes will be powered by hydrogen fuel cells in the very near future,” said Dr Meyer.
“By redesigning hydrogen fuel cells, lightweight aviation becomes a lot more realistic,” added Professor Zhao.
The team is initially targeting low-altitude aircraft as a practical starting point, but the technology could also be applied to heavy transport, marine and industrial applications.
A technology to watch for future fleet planning
For Fleet Managers developing long-term decarbonisation strategies, hydrogen remains a technology to monitor rather than an immediate operational solution.
Most organisations are still in the early stages of improving fleet management maturity — building emissions baselines, understanding utilisation patterns and developing infrastructure plans. In that context, battery-electric vehicles will continue to be the most practical pathway for reducing emissions in the near term.
However, developments like the UNSW fuel cell redesign highlight the importance of maintaining a technology-neutral strategy that considers future options for applications where batteries may not be fit for purpose.
Hydrogen fuel cells are particularly relevant for:
- Heavy vehicles operating long distances
- High-utilisation fleets where downtime must be minimised
- Remote or regional operations with limited grid capacity
- Aviation, marine and specialised industrial applications
The UNSW team has patented the lateral bypass technology and is now working to scale the design for commercial use.
While widespread adoption will depend on hydrogen supply, infrastructure and cost competitiveness, improvements in core technology like this bring hydrogen-powered transport a step closer to practical deployment.
For fleet decision-makers, the message is straightforward: battery-electric vehicles will lead the transition in the short term, but hydrogen fuel cells could play a critical role in the next phase of fleet decarbonisation — particularly for the most demanding operational tasks.
