Direct hydrogen fuel cell electric vehicle cost analysis: System and high-volume manufacturing description, validation, and outlook

Direct hydrogen fuel cell electric vehicles (FCEVs) produce only water as a byproduct, thereby eliminating tailpipe carbon and criteria air pollutant emissions associated with internal combustion engine vehicles (ICEVs). However, in order to achieve economic parity with ICEVs, technological challenges must be overcome to lower system cost. The U.S. Department of Energy (DOE) monitors estimated fuel cell (FC) system cost and tracks progress towards milestones by techno-economic analysis based on demonstrated laboratory technologies for a next-generation 80 kWnet automotive FC stack for light-duty vehicles. The findings of the 2017 automotive FC system cost analysis are summarized, including the baseline system characteristics and specifications and the results of Design for Manufacture and Assembly (DFMA®) analysis of system manufacturing across a range of annual production rates. The highest volume predictions, for 100,000 and 500,000 units per year, result in a total system cost of $50/kWnet and $45/kWnet, respectively. The assumptions and methodology of the DFMA® analysis of the 2017 baseline FC system were validated by comparison with the FC system in the commercially available Toyota Mirai. One prospective pathway for decreasing system cost to $30/kWnet needed for cost competitiveness with ICEVs is outlined.