Public Funding for Microcab Industries Limited

The HySMART (Hydrogen Stack Manufacturing using Advanced Robotics Technology) feasibility project is driven by an urgent need for fuel cell (FC) system producers and associated supply chain to drive down cost from \>€150/kW to <€50/kW (2025), and <€45/kW (2030) at 100k units/yr. (HE.2018), enabling FC vehicles to be offered on a cost competitive basis. Current processes are bespoke and limited in volume and size, providing limited opportunities to reduce costs, with current commercial sales of global automotive FC's -- in 1,000's/year. This project will study real-world applications of automation and inline testing for volume production of hydrogen FC stacks, to include end user requirements. Focusing on the development, integration and application of robotics, software controls and machine learning solutions for producing FC stack technologies. This will be achieved through a feasibility study to include: * Developing a technology roadmap to demonstrating robotics stack manufacturing FC capability * Key component development (MEA's, endplates, bi-polar plates) for in-house automated production to feed into final modular stack manufacture * Implementation of advanced inline testing capabilities, to provide a no faults forward stack production capability * Analysis of co-operative interaction capabilities and associated learnings in this key area of the FC system production process * Developing advanced automation concepts in 3D and test virtual manufacturing scenarios (digital prototyping) * Study end user requirements specific to active implementation into light/medium duty automotive applications The main HySMART deliverable will be key outputs from a comprehensive demonstrator study, detailing advanced product designs and validating key technical challenges; developing FC components ('design for assembly/disassembly'), installation/implementation of in-house robotics manufacturing, and inline testing capability producing high quality conformable modular FC stacks for light/medium duty vehicle applications. HySMART will result in the following benefits: * Instill automotive sector confidence in hydrogen FC technology, accelerating commercial uptake. * Provide industry stakeholders (manufacturers, OEM's, supply chain, etc.) with the operational and technical requirements of using advanced robotics in UK FC stack volume manufacture. * Enhanced conformational capabilities for FC stack developers to provide diverse and system range. * Roadmap to production of working robotic FC stack demonstrator with enhanced inline testing capabilities. * Implementation and roll-out of novel production processes, providing advanced cost-effective modular FC stack systems. * A FC stack system architecture, manufacturable by automation, delivering improved efficiency, and reproducibility. * Opportunities to develop and expand products into additional markets and sectors. Total project size will be £800,607, last 12 months and involve 5 UK partners (Bramble Energy, Microcab, Loop Technology, UCL and HSSMI).

The project centres on the exploration of a new commercial model for the Microcab hydrogen Fuel cell vehicle whereby the vehicle is not sold out right to customers, but offered through a car club scheme for members to hire. Microcab will retain ownership of the vehicle, and implement a remanufacturing model to ensure that the vehicle’s value is recovered back to an original or upgraded condition, resulting in the extension of the vehicles life in service. This project will bring together 3 disruptive business models - circular economy, low carbon vehicles, and mobility as a service - into one complimentary commercial model which will provide benefits for multiple stakeholders.The 3 main deliverables of the feasibility study will be: 1) a full business plan which details the commercial models and provides rigorous evaluation of the most potentially prosperous business model analysed during the project, 2) a series of peer-reviewed white papers that will be made available for the general public, and 3) a pilot plan for demonstrating the model in the form of a business roadmap and technical implementation plan

The proposed project aims at generating new knowledge in establishing how Hydrogen Fuel cell systems (HFC) in Fuel Cell Electric vehicles (FCEVs) can be recovered once they reach the end of their life (i.e. are worn out/have failed) so that their optimal value can be recuperated and their life in service can be kept in circulation to ensure sustainability. As part of the automotive industry's on going efforts to lower CO2 emissions by 80% before 2050, many vehicle manufacturers, such as Hyundai, Toyota, and Honda have started to turn their attentions towards the development of zero carbon emitting FCEVs. It is anticipated that by 2030 there will be in excess of 1.3milion FCEVs on UK roads, and by 2050, will account for up to 30% of the total vehicles on UK roads. When these vehicles reach the end of their life, the automotive industry and producers of the fuel cells will become accountable for the responsible collection, recovery and disposal of them under the ELV directive. At present, little research has sought to establish how to do this. This project is focused on the development of new product, process and business designs to enable fuel cell recovery.