Metier and Mahle to showcase hydrogen conversion project
Hydrogen specialist Metier Technologies and engineering services consultancy Mahle Powertrain have announced plans to unveil a new hydrogen-powered commercial vehicle at next week’s Cenex Expo, the low carbon and connected automated mobility event.
The project is set to demonstrate how the companies’ joint technologies will allow diesel trucks to be rapidly converted to run on 100 per cent hydrogen fuel.
A demonstration vehicle to be showcased at the event will feature a 6.7-litre, six-cylinder engine in a DAF LF220 platform, which the partners have converted to hydrogen technology.
The project employs Mahle Powertrain’s Flexible ECU (MFE) engine control software platform, developed for use in a wide range of internal combustion engine (ICE) applications, which serves as the foundation for rapid conversion to a hydrogen-powered system. The control system enables the precise mapping and calibration needed for hydrogen combustion, says Mahle Powertrain, while the ECU technology optimises performance and safety.
Metier’s hydrogen internal combustion engine solution is claimed to offer superior total cost of ownership compared to battery electric and fuel cell alternatives, as well as enhanced capability for longer duty cycles and heavier payloads, and zero-emissions operation enabling access to urban areas where emissions restrictions are in force.
The company has adopted a regional approach targeting established hydrogen ecosystems in the south-west and Scotland, in collaboration with hydrogen providers and in conjunction with government commitments on hydrogen production up to 2030.
The conversion process involves the integration of specialised hydrogen injectors along with engine mapping using the MFE platform, and new safety systems. Mahle Powertrain’s new heavy-duty hydrogen test bed facility in Northampton has been instrumental in completing the engine mapping and performance optimisation ahead of Cenex Expo.
Beyond the event, Metier says it plans to undertake proof-of-concept work by mid-2026 with targeted fleet operators, then expects volume deployment early the following year. The company is in the process of developing partnerships with leasing firms, fleets and hydrogen suppliers with a view to creating a complete commercial ecosystem.
“This project will demonstrate what can be achieved when engineering expertise meets urgent environmental needs,” said James Budgett, managing director of Metier Technologies.
“Working with Mahle Powertrain’s established control technology, we’ve proven that existing diesel trucks can be rapidly converted to hydrogen power, offering depot-based fleet operators a practical, commercially viable pathway to zero-emission transport without waiting for entirely new vehicle platforms.”
Mike Bassett, engineering director at Mahle Powertrain, will make reference to the project during a presentation on hydrogen ICE design, including combustion computational fluid dynamics (CFD) and Mahle Jet Ignition (MJI), at Cenex Expo, which takes place from 3-4 September at UTAC Millbrook, Bedfordshire.
