As hydrogen, methanol and ammonia gain relevance alongside conventional fuels, testing strategies must evolve to address new physical properties, safety risks and performance expectations. This shift is driving demand for modular, application-specific test systems capable of replicating real-world operating conditions with high precision.

A key challenge lies in the behavior of fuel-contact components under varying thermodynamic and media-specific conditions. Differences in viscosity, compressibility and reactivity between liquid and gaseous fuels require adaptable test environments. Modern systems must therefore combine hydraulic, mechanical and electronic testing capabilities within a single platform.

From component testing to system understanding

Advanced test systems now go beyond basic functional checks, enabling detailed analysis of flow rates, pressure behavior, leakage and long-term durability across components including valves, injectors, pressure regulators, rails and pumps. For injection systems, precise measurement of injection quantities and dynamic flow characteristics is critical.

One example is pressure-based measurement for injection analysis. Systems such as the IAV Cross Injection Analyzer determine injection rates from pressure changes in a fuel-filled channel, enabling dynamic, reproducible measurements without moving parts, reducing maintenance needs while supporting high-resolution data acquisition and real-time integration into digital test environments.

Lifetime and endurance testing also play a central role, with components subjected to mechanical and electronic stress scenarios to assess wear behavior and failure mechanisms over time; insights essential for validating designs intended for series production.

Simulating real-world conditions

A defining feature of modern test infrastructure is the ability to simulate realistic and extreme environmental conditions. Temperature-controlled test chambers enable testing across a wide range – from -76°F to +302°F (-60°C to 150°C) – while additional parameters such as humidity and ambient pressure can be adjusted to replicate specific operating environments.

The combination of environmental simulation with functional testing allows engineers to identify critical interactions early in the development process.

Complementing physical testing, feasibility studies and pre-validation in dedicated development labs help refine test procedures for new applications. This is especially important when dealing with emerging fuels, where standardized testing protocols may not yet exist.

Safety engineering as a core design principle

The introduction of alternative fuels adds significant complexity to safety engineering. Substances such as hydrogen, methanol and ammonia can form explosive atmospheres under certain conditions, making comprehensive hazard analysis essential.

As a result, modern test systems incorporate explosion protection concepts aligned with international standards such as ATEX and IECEx, alongside functional safety requirements defined by Performance Level (PL) and Safety Integrity Level (SIL).

Safety considerations extend beyond the test bench itself. Infrastructure factors such as ventilation systems, gas detection and facility layout are equally important. Effective solutions require a holistic approach that integrates test system design with the surrounding environment, often supported by early-stage risk assessments and coordination with local authorities.

Hydrogen testing and electrolyzer development

Hydrogen technologies add further complexity, particularly in electrolyzer development, where the focus shifts from individual components to entire systems, including single cells and stacks.

Testing requires combining electrical and fluid-based measurement techniques, assessing electrical performance, efficiency and degradation alongside flow distribution and thermal management – a convergence sometimes described as the merging of electronic and fuel testing.

Emerging test concepts support multiple electrolyser technologies, including PEM (proton exchange membrane), AEL (alkaline electrolysis) and AEM (anion exchange membrane). Modular architectures allow scaling across power classes and varying instrumentation levels, suiting both research and industrial pre-series validation.

Modularity as a strategic advantage

Given the uncertainty surrounding future fuel pathways, flexibility has become a key requirement. Modular test systems enable manufacturers to adapt to changing technologies without the need for entirely new infrastructure. Different test methods – such as flow measurement, leak testing and endurance testing – can be combined within a single system and expanded as requirements evolve.

This approach not only reduces investment risk but also accelerates development cycles. By enabling parallel testing and rapid reconfiguration, modular platforms support faster iteration and more informed decision-making.

Outlook

As propulsion technologies diversify, testing is becoming increasingly central to bridging innovation and industrialization. Generating reliable, application-specific data under realistic conditions is critical for performance, safety and regulatory compliance.

The trend is moving away from standardized solutions toward specialized, adaptable test environments, with modularity, safety integration and cross-disciplinary testing capabilities emerging as defining features of next-generation validation systems.

In recent news, Nio opens new UK R&D center in Oxfordshire

The TR LH2 Racing Prototype is based on the same chassis as the TR010 Hybrid Hypercar, which will compete in the Le Mans 24 Hours on June 13 and 14. The prototype is designed to support the development of hydrogen technology in motorsport, contribute to Toyota’s ongoing hydrogen research and infrastructure efforts and help foster partnerships aimed at expanding hydrogen applications through motorsport.

Toyota has taken on the challenge of hydrogen engine development in motorsports, initially through Rookie Racing’s participation in the Japanese Super Taikyu series with the ORC Rookie GR Corolla H2 Concept. From 2021, this vehicle used gaseous hydrogen before the introduction of a liquid hydrogen-powered car in 2023.

The potential of hydrogen engines in rallying was initially showcased in 2022 when the GR Yaris H2 completed demonstration runs at Ypres Rally, a round of the FIA World Rally Championship. Further development was highlighted when the GR Yaris Rally2 H2 Concept conducted demonstrations at the 2025 Rally Finland and this year’s Monte Carlo Rally.

In 2023, the ORC Rookie GR Corolla H2 Concept completed a demonstration lap of the Circuit de la Sarthe, and a hydrogen engine concept car, the GR H2 Racing Concept, was presented to preview a potential future hydrogen category at Le Mans. Since then, development of the technology has intensified, reaching a further milestone with the unveiling of the liquid-hydrogen-powered GR LH2 Racing Concept last year at Le Mans. A year later, the next step in the company’s hydrogen journey is the first public demonstration of the TR LH2 Racing Prototype.

The TR LH2 Racing Prototype will be displayed in the Hydrogen Village before its demonstration laps.

In related news, Project Cavendish: Mahle hydrogen-fueled 13-liter engine matches diesel performance

MissionH24 aims to demonstrate the performance and competitiveness of hydrogen technologies under real racing conditions, with the aim of creating a zero-CO₂ emission category at the 24 Hours of Le Mans. With the support of AVL Racetech, the plan is to develop the H24EVO prototype in a targeted manner.

Pierre Fillon, president of the Automobile Club de l’Ouest and co-president of MissionH24, said, “AVL’s involvement alongside MissionH24 demonstrates the value of our program; the search for decarbonized solutions is essential. AVL’s established reputation in the automotive sector lends tremendous credibility to MissionH24. This collaboration promises to be invaluable.”

AVL Racetech will support the project as a technical partner, bringing its extensive experience in virtual vehicle development. A key element of this contribution will be the AVL VSM Race advanced vehicle simulation software. The fully dynamic simulation platform enables the virtual representation and analysis of complex interactions between the complete vehicle, the powertrain and the energy management system. It therefore reportedly supports the seamless integration of user-defined algorithms into VCU software-in-the-loop (SIL) and hardware-in-the-loop (HIL) workflows specifically designed to optimize the powertrain performance and energy management strategies of the H24EVO race car.

Jean-Michel Bouresche, CEO of H24Project and co-president of MissionH24, added, “AVL will strengthen MissionH24’s pool of technical partners, all of whom are recognized players in the automotive sector. AVL’s skills and expertise will undoubtedly enable us to achieve MissionH24’s ambitious goals.”

Looking ahead, the technical collaboration is planned to be extended from the virtual environment into full vehicle testing. The partners say that the alliance between AVL Racetech, H24Project and ACO as part of the MissionH24 program is a long-term commitment, with a partnership agreement for the next three years.

Ellen Lohr, director motorsport at AVL List, commented, “AVL Racetech is an established engineering partner in 17 top-tier racing series worldwide. We are connected with the MissionH24 by our shared vision of enabling sustainable motorsports and demonstrating that innovative technologies are tangible, feasible and competitive on the racetrack.”

In related news, Johnson Matthey opens cutting-edge hydrogen ICE test facility in Sweden

Martin Kaufmann, head of powertrain development at BMW, said, “Our goal is always to have more environmentally friendly and efficient vehicles on the road. With the diesel replacement fuel HVO100, we have an opportunity to reduce the CO2 footprint of vehicle fleets. Especially in the area of fuels that are not based on fossil fuels, we see potential that we are ready to realize.”

Bernhard Kuhnt, head of sales region Europe at BMW, added, “Fleet customers are extremely important for sales in Europe, and at the same time diesel remains a very good powertrain technology for many fleets. The use of HVO100 offers a way to quickly reduce CO2 emissions that takes into account individual use cases – whether driving long distances or towing a trailer – and can thus help our fleet customers reduce their CO2 footprint.”

Initial contractual agreements with the operators of large BMW diesel fleets in Germany and Italy are imminent, the company has said. These test fleets, together with the internal BMW Group fleet that has already been launched, will provide important data and findings to improve the technical solution.

Since January 2025, all BMW diesel models produced in Germany have been filled with HVO100 before delivery to dealers. Neste MY Renewable Diesel HVO100 is used at the BMW Group plants in Munich, Dingolfing, Regensburg and Leipzig.

The fuel from Finnish manufacturer Neste enables a CO2e reduction of up to 90% well to wheel, compared with fossil diesel. The initial filling at the plants before delivery to BMW Group dealers is five to eight liters, depending on the model.

Regulatory framework conditions must catch up

To accelerate the uptake of renewable fuels across the market, BMW is calling for the Renewable Energy Directive (RED III) – including national quotas that require at least a 30% reduction in greenhouse gas emissions from fuels – to be transposed into national law by 2025.

Dr Thomas Becker, head of policy, external relations and sustainability at BMW, stated, “The BMW Group demands that every measure to reduce CO2 emissions is taken into account at every stage of a vehicle’s lifecycle. This also includes the use of renewable fuels – especially for vehicles that primarily run on CO2-neutral fuel (CNF). These must be formally recognized in EU fleet legislation. The fuels are available; what we need now is a pragmatic and quickly implementable regulation that enables companies to develop innovations and make them marketable.”

In related news, prototype production of BMW’s third-gen hydrogen fuel cell begins, with series production in sight

The Future of Automotive Testing Conference

This day of high-level content will explore various topics and provide an engaging opportunity to learn from and connect with industry peers. Situated among the exhibits, it will have a relaxing atmosphere, and visitors will be able to dip in and out at their leisure. A highlight will be ATTI’s on-stage interview with Jon Quigley, who worked for Volvo for many years and now runs his own company, Value Transformation. With his broad experience and portfolio of contacts, he’s a very good person to know. He loves sharing his thoughts, too, hence his new gig as ATTI’s regular columnist.

Read Quigley’s latest column on p36 of the September issue.

Also during the conference, Venkat Adusumalli, software engineering manager at Stellantis, will reveal how Stellantis is using AI to accelerate E/E system testing and validation workflows. Click here for a pre-show interview with him.

Innovation Showcase

The free-to-attend Innovation Showcase also provides an interactive platform for learning about new technologies. Speakers will welcome questions and discussion after their presentations, making it a great way to explore ideas together. Like the conference, it will take place within the main hall, so it will be very easy to listen in while wandering through the exhibits, or to come and go throughout the day.

Technology debuts

The industry is moving quickly and it can be a challenge to keep up. Every year there is an abundance of new technologies on display. Some are incremental improvements to existing products, others are entirely new. It’s always surprising how companies find ways around bottlenecks. Often, these developments emerge from ongoing conversations between supplier and customer, ultimately benefiting multiple companies.

Read ATTI‘s comprehensive expo preview in the September issue.

Face-to-face discussions  

It sounds obvious, but the most fruitful conversations are usually the ones that happen in person – it’s how journalists find the best stories. Year after year, exhibitors and visitors report having forged unexpected collaborations at the show, in the form of technology tie-ups or service partnerships.

Detroit’s revival 

A lot of money has been plowed into Detroit in recent years, as evidenced by the stunning renovation of Michigan Central Station, which is well worth a visit. Much of the investment has been in the tech sector. Eleven years ago – when the station was still derelict – ATTI took a tour of some of the labs at GM and what was then the FCA headquarters (see The right wave length, November 2014, Seasonal highlights, September 2015, and Powerbase, March 2015). The facilities were impressive then and are even more so now, thanks to several years of investment in innovation leading to Detroit’s resurgence as an automotive powerhouse.

Visit the Automotive Testing Expo North America website to secure your FREE pass, which will give you access to the expo, the Future of Automotive Testing Conference and the Innovation Showcase

The growth of a large-scale hydrogen economy poses challenges for measurement technology. Hydrogen diffusion and accumulation can cause material embrittlement, while infiltration into sensor elements may distort measurement accuracy.

Combustion engines operated with hydrogen or alternative H₂-based fuels are almost emission-free, paving the way for decarbonized mobility – with engine developers using hydrogen-resistant sensors to optimize hydrogen combustion – and Kistler’s hydrogen pressure sensor has been designed to support this mobility transition. The sensor can be used for gas exchange analysis as well as pressure measurement in the low-pressure fuel supply rail of hydrogen engines.

The 4012A sensor enables hydrogen pressure monitoring in the low-pressure range of fuel cells, with piezoresistive absolute pressure sensing available in two ranges: up to 20 bar and 50 bar.

In related news, Comemso electronics has launched SmartCal, a solution for calibrating and adjusting its in-house battery cell simulator (BCS)

The opening ceremony for the eCampus facility at its Stuttgart-Untertürkheim headquarters in Germany was attended by German federal minister of economic affairs Robert Habeck and Baden-Württemberg minister-president Winfried Kretschmann.

The eCampus will develop new chemical compositions and optimized production processes for high-performance battery cells. The facility encompasses the entire product and process chain of cell development and production, enabling the development of expertise for economical manufacturing processes.

Mercedes says it is investing €14bn (US$15bn) in 2024 into research and development and its plants, with a large portion allocated to battery and electric drive system advancements. These investments aim to strengthen Stuttgart-Untertürkheim as a high-tech location for drive technologies, and support the auto maker’s sustainability business strategy – the new facility has been constructed with recycled concrete and features a green roof and photovoltaic systems.

Ola Källenius, chairman of the board of management of Mercedes-Benz, emphasized the strategic importance of the eCampus: “The opening of the Mercedes-Benz eCampus marks an important step in our sustainable business strategy. It is our ambition to also play a leading technological role in electric mobility. The eCampus brings us closer to this goal. The work carried out here will help to reduce battery costs by more than 30% in the coming years.”

Focusing on various forms of cell chemistry, the facility will develop lithium-ion cells with high-energy anodes based on silicon composites and cobalt-free cathode chemistries, as well as solid-state battery technology. The aim is to develop cells with high energy density, fast-charging capability and superior performance.

Operations at the eCampus will start in two stages. The first stage includes a 10,000m² factory for industrial-scale battery cell production, which has commenced operations. The second stage, due for completion by the end of the year, will house a battery ramp-up factory for product and process development as well as a test and proving center.

The plant already produces flexible drive systems for both fully electric and electrified vehicles and is responsible for a large part of the group’s drivetrain R&D.

Robert Habeck, German federal minister for economic affairs and climate action, said, “High-performance batteries comprise the heart of the electrification of transport – and are the key to the successful transformation of the automotive industry. The demand for innovative and sustainable batteries will continue to rise sharply in Europe in the coming years.”

Markus Schäfer, member of the board of management of Mercedes-Benz and CTO, outlined the comprehensive R&D expertise at the eCampus: “At the new eCampus, we can pool and expand our comprehensive research and development expertise across the entire electric drive system even more effectively. This offers us new opportunities for sustainable innovations in cell chemistry.”

The forum will be a vibrant hub where enthusiasts, experts and newcomers alike can converge to explore, share and connect on all things automotive testing and development. You can expect discussions on cutting-edge analysis technologies and industry trends, and passionate debates. The program will offer an afternoon of high-level content and will be followed by the first-ever live ATTI Awards ceremony.

Here’s what’s in store:

2:30pm
Welcome

2:40pm
Panel discussion – Exploring the future of automotive testing
Moderator: Dr Huw Davies, senior lecturer at Coventry University’s Centre for Future Transport and Cities

Gemma Hatton, freelance technical writer
Phil Durston, technical manager, Volkswagen
Nils Katzorke, project manager, Mercedes-Benz

3:20pm
In conversation

Jahee Campbell-Brennan, director, Wavey Dynamics
• AI-driven simulation is revolutionizing vehicle development
• How to gain actionable insights by using AI in testing
• The challenges in adopting AI-driven testing solutions

Plato Pathrose, CTO and technical director, ADAS and AD, Vinfast Germany
• The key hurdles of connected, software-defined and autonomous vehicle simulation
• How to formulate a successful simulation program
• Mature simulation platforms vs the latest collaborative platforms

4:00pm
ATTI Awards ceremony
Drinks and canapés will be served.

For more information, visit the Automotive Testing Expo Europe website.

Petroleum and natural gas company Aramco is evaluating an investment in the new powertrain business, after signing a letter of intent with Renault and Geely in March this year. This would support the growth of the company and contribute to key research and development in synthetic fuels and next-gen hydrogen technologies.

Other supply chain partners are encouraged to get involved.

With an equal share in the new entity, a team from each of the OEMs will work together to lead operations: one in Madrid, Spain for Renault Group and one in Hangzhou Bay, China for Geely. There are plans to establish a new headquarters in the UK, which will be home to an executive team.

Renault Group and Geely will transfer intellectual property to the operational centers enabling them to be fully autonomous. The new joint venture’s complementary product portfolio and regional footprint could offer solutions for 80% of the global ICE and hybrid market, according to the companies.

Geely Auto and Renault plan to secure a long-term procurement agreement from the joint venture for ICE, hybrid and plug-in hybrid powertrains (engine and transmissions) for passenger vehicles. Renault will also procure powertrains for its light commercial vehicles and hybrid batteries. The new entity will supply several brands under the Renault/Geely umbrella: Renault Group, Geely Auto, Volvo Cars, Proton, Nissan, Mitsubishi Motors and Punch Torino. In the future, the aim is to provide complete powertrains for third-party customers as well.

Luca de Meo, CEO of the Renault Group, said, “Facing today’s automotive challenges, no one can claim to have all the solutions, alone. Coming up with breakthrough innovations requires combining expertise and assets. When it comes to the global race for decarbonizing road transportation, there is no time to lose, and it will not be business as usual. Today, we are proud to join forces with a great company like Geely to set up a new player, up to the challenge, able to disrupt the game and open the way for ultra-low-emissions ICE technologies. I want to thank Eric Li Shufu for his trust; we are now ready to move forward.”

Eric Li, Geely Holding Group chairman, commented, “We are pleased to be embarking on this journey to become a global leader in hybrid technologies, providing low-emission solutions for auto makers around the world. We are looking forward to working with Luca de Meo and his team. With this agreement, we reiterate our commitment to leveraging our group-wide technological expertise and brand portfolio to pioneer the journey to greater sustainability and value creation, which will lead to better consumer experiences.”

The e-fuel being tested is drop-in replacement, synthetic fuel produced from captured atmospheric CO₂ and renewable energy. Through the adoption of e-fuels, owners of ICE vehicles could easily and affordably reduce vehicle emissions without needing to purchase a new vehicle, fit any supporting upgrades or wait for new infrastructure to be built.

The 28 engine families – built from 2014 onwards – being tested and validated include both petrol and diesel variants. Testing is conducted on the powertrain’s tailpipe emissions, start-ability, engine power, reliability endurance, oil dilution and on the fuel tank, fuel lines and filters, among others.

If the 28 million vehicles fitted with Stellantis powertrains transitioned to the use of e-fuel, the manufacturer predicts that CO₂ emissions in Europe could be reduced by 400 million tons from 2025 to 2050.

“We are doubling down on our fight against global warming by testing carbon-neutral fuel as a complementary solution to our holistic decarbonization approach,” said Carlos Tavares, CEO, Stellantis.

“While we remain steadfast in executing our aggressive electrification strategy, we must also find smart alternatives to address the CO₂ emissions for the 1.3 billion existing ICE cars. By working to make sure our Stellantis engines are e-fuels friendly, we are aiming at giving our customers another tool in the fight against global warming and one that can have an almost immediate impact. It is also another action we are taking that is well aligned with our commitment to be carbon neutral by 2038.”