The global automotive industry is rapidly transitioning toward zero-emission powertrains, with fuel cell electric vehicles (FCEVs) playing a critical role. By 2030, over 60 million fuel cell vehicles are expected to enter the market, driven by increasing demand for sustainable mobility and government policies.
By 2040, fuel cell vehicles will capture a significant market share:
6% in 2030, exceeding 20% by 2040
3% in 2030, rising to 14% by 2040
Less than 2% in 2030, increasing to 14% by 2040
Less than 1% in 2030, projected to reach 10% by 2040
Fuel cell electric vehicles (FCEVs) produce no carbon dioxide (CO2), nitrogen oxides (NOx), or particulate matter during operation. The only byproduct is water vapor, making them a truly zero-emission alternative to gasoline and diesel-powered vehicles. As countries move toward stricter environmental regulations and climate neutrality goals, hydrogen-powered fuel cells will play a crucial role in achieving a cleaner, more sustainable future.
Unlike battery electric vehicles (BEVs), which can take 30 minutes to several hours to recharge, hydrogen fuel cell vehicles can be fully refueled in just three to four minutes, similar to conventional gasoline or diesel cars. This eliminates long wait times at charging stations, making fuel cell vehicles ideal for high-usage fleets, long-haul transportation, and consumers who require quick refueling.
One of the main concerns with electric vehicles is limited driving range and the availability of charging infrastructure. Fuel cell vehicles offer a significantly longer range per refueling, often exceeding 500 to 700 kilometers (310 to 435 miles) on a single tank of hydrogen. This makes them particularly well-suited for long-distance travel, commercial transport, and regions where charging infrastructure is still developing.
One of the main concerns with electric vehicles is limited driving range and the availability of charging infrastructure. Fuel cell vehicles offer a significantly longer range per refueling, often exceeding 500 to 700 kilometers (310 to 435 miles) on a single tank of hydrogen. This makes them particularly well-suited for long-distance travel, commercial transport, and regions where charging infrastructure is still developing.
Hydrogen has an exceptionally high energy density, meaning it can store and deliver much more energy per kilogram compared to lithium-ion batteries. In fact, hydrogen fuel cells provide eleven times the energy density of typical EV batteries, making them a more efficient solution for heavy-duty applications such as trucks, buses, trains, and even maritime transport. This superior energy efficiency enables better payload capacity, longer operational cycles, and reduced downtime compared to battery-electric alternatives.
Machining processes generate over 6 billion Euro of manufacturing value creation in 2040. Major contributors are the balance of plant components (e.g. compressor- expander-motor unit) and the hydrogen feeding parts (e.g. manifolds, valves, lines) required in the balance of plant and hydrogen tank.
Primary shaping processes generate over 2 billion Euro of manufacturing value creation in 2040. Most of the value creation happens within the production of balance of plant components. Further value is created by housing components within the electric powertrain, for example the housings of the electric drive unit or the battery housing.
Joining and assembly processes are present within many fuel cell vehicle components. Major contributors are the balance of plant and the hydrogen system due to the number of parts that are assembled. Also, the fuel cell stack generates nearly 1 billion Euro of value creation. The total value creation is expected to be nearly 6 billion Euro in 2040.
Major forming processes within fuel cell powertrains are used for the bipolar plates and the hydrogen tank. Also, the air and hydrogen guiding systems within the balance of plant require forming processes. The total value created is expected to reach nearly 2 billion Euro in 2040.
Coating processes are primary applied to the fuel cell stack and required for example for the bipolar plates and components of the membrane-electrode-assembly. The total value is expected to reach 0.9 billion Euro in 2040.
Other and special processes also account for nearly 7 billion Euro of value creation in 2040. However, the major contribution is the production of battery cells used within the fuel cell vehicles, followed by electronic components and the composite processing for the carbon- fiber tanks.
The fuel cell industry is poised for massive growth in manufacturing and supply chain development, creating thousands of jobs and driving significant investments. As hydrogen fuel cell vehicles (FCEVs) gain momentum, businesses and governments are making substantial commitments to scale up production and infrastructure.
With the increasing demand for zero-emission vehicles, the fuel cell sector is expected to generate over 60,000 new jobs, including 15,000 jobs in manufacturing. These positions will span across fuel cell production, hydrogen storage solutions, and supply chain logistics, offering new opportunities in the transition to clean energy technology.
To support the rapid expansion of fuel cell vehicle manufacturing, investments in production plants, R&D, and supply chain infrastructure will exceed €8 billion by 2040. This financial commitment will enhance scalability, efficiency, and cost reductions for fuel cell systems, making them a more competitive alternative to traditional internal combustion engines.
The transition to hydrogen-powered vehicles is accelerating due to government incentives, stricter CO2 regulations, and advancements in fuel cell efficiency. As key markets invest in green hydrogen infrastructure, fuel cell vehicles will play a central role in the future of sustainable transportation.
Now is the time to invest in fuel cell technology to stay ahead in the growing zero-emission vehicle market.
2020 | Michael Wittler, Kai Krüger
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