For over 75 years, AVL has been a recognised leader in the automotive industry, specialising in testing equipment and engineering solutions. As the global energy landscape undergoes significant transformation, AVL is expanding its expertise into industrial energy, hydrogen production, and technology. This move positions AVL as a crucial partner for electrolyzer OEMs, EPC, energy companies, and industrial players looking to integrate hydrogen solutions into their operations. With a strong commitment to innovation, the company offers comprehensive engineering capabilities, simulation tools, and testing solutions that support customers from concept to realisation.

 

Pioneering Hydrogen Technologies

AVL is not just another name in the hydrogen sector; it is setting new industry standards with its comprehensive hydrogen solutions. Decades of engineering and an unwavering drive for innovation allow the company to provide end-to-end support, from initial concept to the engineering of complete plants and provide support in the process.

One of its standout strengths is electrolyzer testing. Whether it’s PEM, SOEC or AEM technology, AVL ensures that systems undergo rigorous evaluations to validate performance, efficiency, and durability. Its electrolyzer testing solutions guarantee that hydrogen production meets the highest quality standards, while stack durability testing provides manufacturers with insights into system longevity and degradation patterns, paving the way for more robust electrolyzers.

A key example of this is AVL’s involvement in the Innovation Future Energy (IFE) initiative, where development and integration of CO-electrolyzer technology and its corresponding testing infrastructure played a vital role in ensuring highest efficiency and durability. This collaboration is part of Austria’s wider push for E-Fuel (SAF) production, ensuring that AVL’s expertise directly contributes to real-world advancements in green energy solutions.

“Testing isn’t just about validation – it’s about continuous improvement. By analysing system performance under real-world conditions, we help manufacturers enhance efficiency, reliability, and scalability,” explains Radhika Velayudhan, System Line Manager – Electrolyzer Testing.

 

 

AVL’s experience extends beyond electrolyzer testing to fuel cell validation as well. Projects like the Hydrogen Innovation Center (HIC) for HZwo and the AVL Test Factory in Graz showcase AVL’s ability to develop scalable, future-proof testing environments that support both fuel cell and hydrogen research. The HIC project involved feasibility studies and infrastructure development for an industrial research and certification facility, while the Test Factory in Graz highlights AVL’s cutting-edge fuel cell testing capabilities, integrating multiple testbeds and flexible hydrogen supply solutions.

 

Model-Based System Testing

AVL’s containerised electrolysis system testbed denotes a holistic testing solution for complete electrolysis systems in the range of up to 5MW that seamlessly integrates into their proven toolchain for automation, calibration, simulation and data analytics. Its electrolysis system testbed is the ideal development platform to front-load engineering tasks and improve the electrolysis system’s robustness and efficiency.

Simulation is another area where AVL excels. Model-based development methodologies transform how engineers design hydrogen systems, allowing them to front load engineering tasks already in the concept phase before a single prototype is even built. Furthermore, AVL’s 3D CFD simulation solutions allow for the microscopic analysis of individual cell behaviours, enabling fine-tuning of cell geometry and material selection in a virtual environment.

“We don’t just test and analyse; we provide actionable insights that drive real-world performance improvements. Our testbeds and real-time monitoring tools enable manufacturers and plant operators to validate electrolyzer performance and to track degradation, optimise operational efficiency, and ensure long-term system reliability,” Radhika adds.

These cutting-edge innovations solidify AVL as a premier partner, empowering its customers to advance hydrogen energy into a new era.

 

Engineering Capabilities: Fuel Cells and Electrolyzers

Hydrogen technology expertise at AVL spans the entire value chain, from cell development to full-scale system integration. This means it doesn’t just evaluate electrolyzers – it enhances and optimises them.

AVL’s engineering capabilities extend to advanced systems engineering, ensuring that all components of electrolyzer and fuel cell systems are integrated for optimal performance and long-term reliability. This approach helps meet the evolving demands of the industry.

 

 

In addition to systems engineering, AVL offers Testing-as-a-Service infrastructure, providing a flexible and scalable testing environment for electrolysis systems. Through advanced data analysis and reporting tools, real-time insights are provided, allowing manufacturers to track performance, optimise operations, and ensure long-term system reliability. These insights enable informed decision-making and the refinement of system designs for better efficiency.

 

Simulation Tools: The Power of Digital Twin Technology

Why rely on costly prototypes when performance can be perfected virtually? AVL’s simulation expertise allows manufacturers to fine-tune electrolyzer efficiency in a digital environment before implementing physical changes.

AVL’s simulation methodology and the 1D multidisciplinary system simulation tools have been developed and validated based on real-world measurements. The electrolyzer stack and gas path feature a real-time capable, multi-domain, and multi-scale modelling approach that accounts for thermodynamic, chemical, and electrochemical processes. This, combined with Design of Experiments (DoE) – a structured, systematic approach to testing and optimising electrolyzer performance.

“With DoE, we can optimise hydrogen production efficiency by testing multiple parameters simultaneously, rather than in isolation. This not only accelerates development but also provides deeper insights into performance optimisation and degradation mechanisms,” Radhika says.

By leveraging DoE and simulation, AVL identifies optimal operating conditions, reduces testing time, and enhances system reliability while accelerating development cycles. This powerful combination ensures that AVL’s digital twin technology provides a comprehensive, data-driven framework for electrolyzer design and optimisation, helping manufacturers improve hydrogen production efficiency and system longevity before a single prototype is built.

 

 

A Unique Market Position: Full Value Chain Expertise

What makes AVL stand out? It’s not just about technology – it’s about a holistic approach. Unlike tier-one suppliers focused on electrolyzer stack manufacturing, AVL positions itself as a true development partner. Rather than competing with electrolyzer manufacturers, AVL provides them with the tools, insights, and expertise to optimise their own systems.

Offering full-system integration capabilities, AVL ensures that electrolyzer technology is not just functional but also future-proof. Its ability to tailor solutions based on specific customer needs allows it to address unique challenges, making it a trusted innovation partner in the hydrogen sector.

 

AVL’s Commitment to Innovation

AVL’s expansion into hydrogen technology is more than just a business move – it’s a commitment to shaping the future of clean energy. By providing a powerful combination of engineering, testing solutions, and simulation, the company equips electrolyzer manufacturers and operators with the resources they need to excel in a fast-evolving industry.

With advanced simulation technology, advanced degradation monitoring and cutting-edge testing solutions, it is redefining how electrolyzer systems are designed, tested, and optimised.

As Radhika puts it, “At AVL, we believe in empowering our customers with tools and insights they need to thrive in the hydrogen economy. Our mission is to optimise hydrogen technology through precise testing and data analysis, enhancing performance, reliability, and scalability for a sustainable future.” •