T H E AV L M O B I L I T Y T R E N D M A G A Z I N E
2 0 2 5
AI as the
New Engine of
Mobility Innovation
From Code to Road:
Developed, built, and tested in just twelve
months, the AEE 1 demonstrates how AVL is suc-
cessfully transferring its automotive know-how
into the energy sector.
AVL combines engineering, simulation, and
testing expertise to help OEMs and brake
system suppliers not only comply, but also
create cleaner, safer, and more innovative brake
systems.
AVL’s First
In-House PEM
Electrolyzer Stack
Meeting Euro 7
Standards
Artificial intelligence is redefining how we create value, make
decisions, and innovate. It is not a question of if we use AI, but how
responsibly and effectively we do so.
Lukas Walter returns to AVL as Chief Operating Officer
Engineering. In this interview, he shares how curiosity,
responsibility, and innovation drive change.
AVL delivers a modular software toolchain that empowers
OEMs and suppliers to efficiently test and calibrate vehicles
and their components.
Horse, born from Renault’s spin-off with Geely, is
transforming Valladolid into a hub for next-generation
hybrid technologies, supported by over 100 AVL engineers
advancing efficient, reliable, and sustainable mobility.
EDITORIAL AND CONTENT
AI as the New
Engine of Mobility
Innovation
“Sometimes You
Just Have to Skip
the Hierarchy”
EVolve Mobility:
Faster from Lab to Road
A New Era in
Hybrid Powertrains
22
04 From Code to Road: AI as the New Engine
of Mobility Innovation
06 Between Promise and Responsibility:
The Rise of AI-Driven Vehicle Development
CORPORATE INSIGHTS
08 “Sometimes You Just Have to Skip the Hierarchy” –
Interview with Lukas Walter
10 AVL Tech Center Steyr: Driving the Future of
Commercial Mobility
12 AVL ZalaZONE Opens New High-Speed Oval
ENERGY AND SUSTAINABILITY
16 AVL’s First In-House PEM Electrolyzer Stack
Hydrogen Innovation Made in Graz and Vancouver
18 HyCentA and AVL: Revolutionizing Hydrogen Technology
Testing Together
19 First Time Right: How Simulation Drives Electrolyzer Efficiency
and Lifetime from Day One
20 AVL Digital Battery Passport: From Regulation to Real-World
Value
21 From Hydrogen to Air Quality: Why Purity Is the Hidden Hero
of Clean Energy and Clean Air
E-MOBILITY
22 Let’s Release! EVolve Mobility: Faster from Lab to Road
24 AVL Battery Cell Testing: It’s All About Better Batteries
60
04
08
16
40
2 | 3
Dear
Readers,
Innovation is strongest when it is shared. At AVL,
collaboration with customers, partners, and research
institutions has long been the foundation of our
progress. Today, this collaborative spirit gains a new
dimension with the rise of artificial intelligence. AI is
no longer just a tool; it is becoming a true partner that
expands human creativity, shortens innovation cycles,
and enables us to tackle challenges once thought
insurmountable.
Yet, as with every partnership, success depends on
trust and responsibility. Technology alone cannot
define the future. It is how we choose to apply it –
transparently, ethically, and with foresight – that
determines its value for society. For our customers, AI
opens entirely new possibilities to handle complexity,
speed up product validation, and bring innovations
to market faster. It helps to develop vehicles that are
cleaner, safer, and more intelligent throughout their
lifecycle – from design and testing to operation in the
field. For AVL, this means that AI can amplify what we
do best as engineers and innovators, while reminding
us that judgment, creativity, and responsibility remain
essential.
This edition of FOCUS reflects that broader horizon.
Alongside the opportunities of AI, you will find insights
into electrification, hydrogen and fuel cell development,
next-generation vehicle systems, motorsport, and the
global activities of our affiliates. Each story illustrates
that the future of mobility is not shaped in isolation, but
through an ecosystem of ideas, disciplines, and people
working together across the globe.
For AVL, the path forward is clear: combine engineering
excellence with digital intelligence, strengthen
collaboration as the catalyst for progress, and never
lose sight of our responsibility toward people and
planet. In doing so, we aim to turn potential into lasting
impact – for industry, for society, and for generations
to come.
I hope this magazine inspires new perspectives on how
together technology and responsibility can reimagine
mobility.
Prof. Helmut List
Chairman and CEO, AVL
26 Electrochemical Modeling: Redefining Battery Simulation
27 Electrified Powertrain Integration: Two Paths in Focus
28 High-Speed and High-Efficiency EDUs: Driving Innovation in
E-Mobility
30 Over 99.6 % Efficiency: VisIC Technologies and AVL Set New
Standards in GaN Inverters
31 Ready for Take-Off: Validating the Future of Electric Aviation
33 MORELife Project: Unleashing the Potential of Fuel Cells
FUTURE ICE SOLUTIONS
34 Hybrids and Range Extenders: More Than Just Bridging
Technologies?
36 Achieving IMO CO2 Targets: Converting Traditional Engines to
Alternative Fuels for Maritime Decarbonization
38 Future-Ready Testbeds: Modernization with AVL
39 Pioneering PEMS Testing on Motorcycles in India
NEXT GENERATION VEHICLES
40 We Take Care of Brake Wear: Meeting Euro 7 Standards
42 Steer-by-Wire: Turning the Wheel into the Future
45 AVL ThermalLab™ Is Tackling the Thermal Challenge in BEVs
45 New AVL Tilting Powertrain TS™ Is Expanding the Limits of
E-Powertrain Testing
46 Redefining the Vehicle Backbone: AVL’s Approach to SDV E/E
Architectures
47 Modular Vehicle Testbeds: A Turnkey Solution for Faster Testing
48 Vehicle Interior Air Quality: A Breath of Fresh Air for Vehicle
Development
49 AVL Prime Mover: How AVL Took the Lead in
F1 Transmission Testing
AUTOMATED AND CONNECTED MOBILITY
50 Verification & Validation for ADAS/AD: A Multi-Pillar Approach
for Safe and Scalable Mobility
52 Beyond Infotainment: SDV’s Hidden Impact on Development
and Testing
53 TERRA-V: Optimizing Autonomous Mobility in Off-Road
Environments through Virtual Testing
54 Cyber Security for All Mobility Sectors, Across Every Maturity
Stage
AVL RACETECH
56 go_RACE™ – Changing the Game
58 Multi-Sim: Teaming Up for the Future of Race Simulation
GLOBAL FOOTPRINT
60 From Valladolid to the World: A New Era in Hybrid Powertrains
62 Driving Infrastructure Innovation for a Sustainable Future
63 Acquisition of New Customer:
HOPPECKE SYSTEMTECHNIK GmbH
64 Japan Technical Center Is Driving Innovation
65 AVL Japan Opens First Skills Center in Nagoya
66 Tackling India’s Battery Testing Challenges
68 PRODUCT AND SOLUTION HIGHLIGHTS
2025
COVER STORY
cross industries, AI is reshaping processes, business
models, and leadership logic. It enhances productivity
and accelerates innovation cycles, while also raising
new questions about skills, responsibility, and trust. For Europe
in particular, the challenge lies in avoiding passivity. A culture
of regulation without decisive action risks leaving innovation
and market leadership to other regions.
Education plays a central role in ensuring sovereignty. Digital
resilience is not built in data centers but in classrooms. Young
people must learn how algorithms work and how to reflect on
their implications. Repetitive entry-level tasks in many profes-
sions, once essential for building judgment and expertise, are
increasingly automated. The risk is not that machines think
better, but that humans stop learning to think for themselves.
Artificial intelligence is not just another wave of digitalization.
It marks a fundamental shift that is transforming economies,
societies, and even our self-perception. Unlike previous
technology trends, AI is spreading at unprecedented speed
and depth, redefining how we create value, make decisions,
and innovate. It is not a question of if we use AI, but how
responsibly and effectively we do so.
AI as the
New Engine of
Mobility Innovation
From Code to Road:
4 | 5
Business as Bridge Builders
Companies carry a special responsibility for connecting
technology with values and responsibility. AI must not be
reduced to a tool of efficiency but understood as a strategic
enabler.
At AVL, this means combining engineering expertise with
advanced methods in simulation and testing. AI does more
than accelerate processes – it transforms how knowledge
is applied to create enterprise value. By codifying expertise
and enabling seamless collaboration, AI shortens time to
market, improves quality, and strengthens long-term com-
petitiveness. At the same time, trust is essential: only sys-
tems that are transparent, verifiable, and explainable can
serve as a reliable foundation for future business success.
Relevance for the Mobility Industry
Few sectors illustrate the transformative power of AI as
clearly as mobility. Across the entire value chain, AI drives
innovation, enables sustainable business models, and safe-
guards competitiveness in a global market.
For companies, this also means a redefinition of value
itself. Data, algorithms, and platform effects are becoming
strategic assets, intangible yet decisive for enterprise suc-
cess. Leaders must learn to evaluate these new forms of
capital while ensuring that compliance, safety, and societal
acceptance remain intact.
Shaping the Future with Responsibility
AI is a mirror of our thinking. It reflects the values and
responsibility with which we use it. The real risk is not
the technology itself but our passivity, whether through
hesitation, overregulation, or neglecting the education and
empowerment of future generations. To move forward,
three priorities stand out:
• Invest strategically: in research, infrastructure, and skills
to remain competitive
• Embed responsibility: make transparency, fairness, and
accountability core design principles of AI systems
• Foster human learning: ensure that people continue to
develop judgment, creativity, and resilience alongside AI.
Responsibility and strategy must go hand in hand. Only by
combining innovation with accountability can AI become a
trusted partner that creates both societal benefit and sus-
tainable corporate value. For the mobility industry, and for
AVL in particular, this is not an abstract debate. If embraced
with vision and responsibility, AI will not diminish human
ingenuity but amplify it, helping us reimagine mobility as
safer, cleaner, and more sustainable.
Imagination and Courage
Are the True Capital of the
Age of AI
Artificial intelligence is the most profound shift since
Gutenberg’s press. Just as movable type reshaped soci-
ety’s relationship with knowledge, AI is redefining how we
generate insight, make decisions, and create value. It is not
just an incremental tool, but a new grammar of thought
– one that extends our capabilities while shifting parts of
reasoning to systems we must carefully govern.
In mobility, legacy industries are burdened by entrenched
processes, slowing adoption compared to fast-moving sec-
tors like consumer electronics. Overcoming this demands
imagination and courage to rethink structures, redesign
engineering and testing, and pioneer workflows that unlock
innovation despite constraints.
AI is also an engine of discovery. It accelerates research
and simulation, opening frontiers from material science to
predictive vehicle design. What once took years of trial and
error can now be explored in weeks. For leaders, the key
question is not only how to capture efficiency, but how to
invest so that AI expands the frontier of possibility.
However, efficiency gains will not fall evenly. Some will
benefit platforms and productivity; others may free up per-
sonal time. Whether we use it for connection, reflection, or
creativity will decide if AI enriches life or merely accelerates
business.
Imagination and courage will always involve mistakes and
failures. Responsibility in AI does not mean avoiding all
errors, but managing them openly, correcting them quickly,
and turning them into learning. Leaders must create
environments where failure is possible without eroding
trust – where responsibility doesn’t stifle innovation, but
strengthens it.
At AVL, we see ourselves as bridge builders: creating
technology that advances mobility while serving trust, re-
sponsibility, and sustainability. In the age of AI, imagination
and courage are not luxuries - they are the true capital that
turns technology into progress, and the only currency that
secures a future worth having.
by Yorck Schmidt
Chief Financial Officer
2025
COVER STORY
The Rise of AI-Driven
Vehicle Development
Between Promise and Responsibility:
By combining human expertise with data-driven intelligence, AI creates
a seamless link between engineering, simulation, and testing. It not only
accelerates innovation but also enhances quality, reliability, and trust, which
are essential values in shaping the next generation of mobility. FOCUS asked,
Stefan Bruhnke, Roland Wanker, and Jens Poggenburg to shed light on the
significance of this topic and how artificial intelligence is redefining what’s
possible in vehicle development.
Why is AI a true game changer for vehicle development rath-
er than just another tool?
Bruhnke: AI is changing our overall approach to development.
It influences methods, processes, and even how we think
about systems. AI helps shorten development cycles across
the entire chain, from requirements to predictive mainte-
nance. It is the foundation for future concepts such as the
software-defined vehicle.
Wanker: For me, AI is a powerful catalyst. It brings automa-
tion and efficiency into areas that were too complex to handle
manually, especially in simulation. What matters most is that
engineers can access and use information across the organi-
zation faster and more intuitively.
Poggenburg: AI gives us a new level of confidence. It
strengthens the credibility of results, for instance, in ADAS
validation or over-the-air software updates. It also enables
us to align our entire portfolio with AI-enriched methods,
from development tools to customer services. This marks a
fundamental shift.
How is AI changing the way AVL develops, simulates, and
tests vehicles, and how are these areas more closely linked
through AI?
Poggenburg: AI is changing how we work together. It takes
data usage to a completely new level. We can use information
that already exists in the company faster and more effectively,
which makes collaboration across business units much easi-
er. In 2026, we will launch an AI-supported Service Center that
will serve as a direct interface between customers and AVL
experts. It will enable knowledge sharing and problem solving
in real time, making collaboration even more efficient.
Bruhnke: What AI enables is a truly holistic approach. We gen-
erate data from simulations, from tests, and from develop-
ment work itself. With consistent data management, which AI
makes possible, we can connect it all and even feed back field
data into the requirements process. This makes the entire
development more focused.
Wanker: Simulation is already one of the strongest drivers
of efficiency, and AI is pushing that even further. The world
is looking for speed, and AI helps deliver it. It connects data
sources, automates model creation, and enables engineers to
get to results faster.
Can you share examples where AI has accelerated develop-
ment or made new results possible?
Bruhnke: A good example is our AVL Vehicle Composer. It
uses trained AI models to create a Virtual Twin very early on
in development. You can evaluate multiple vehicle attributes
simultaneously and immediately see how a change in one
component affects the overall system. This can shorten
concept phases by up to three months and reduce hardware
prototypes by up to 40 %.
Wanker: One clear use case is virtual calibration in real-time
simulation. Without AI and machine learning, this speed and
precision would not have been achievable.
Poggenburg: In testing, AI supports both parameterization
and planning. We can now use far more data from lab, road,
and fleet operations in a unified process. This expands test
coverage and improves the quality of results. The boundaries
between virtual and physical testing are becoming more and
more fluid.
6 | 7
Vehicle development is becoming increasingly complex.
How does AI help manage that?
Poggenburg: The complexity, especially in ADAS validation
and software testing, is enormous. AI helps us manage that
by identifying the most relevant scenarios and detecting
inconsistencies between software versions. It also supports
engineers in finding new solutions by highlighting connec-
tions we might otherwise overlook.
Bruhnke: Complexity will not go away, but we can handle it
differently. With automated interfaces and consistent data
flow, AI helps us connect all development stages. Our Inte-
grated and Open Development Platform is the backbone for
this, integrating tools and data across domains, making the
process more transparent and the results more reliable.
Wanker: Much of the complexity is caused by delays in get-
ting the right information. AI acts as a catalyst by distributing
and structuring data so that engineers have exactly what they
need at the right time. We are already using it in field analyt-
ics to detect anomalies in vehicle data, which allows us to
pinpoint specific issues rather than analyze entire fleets.
What challenges do you see today?
Poggenburg: The biggest challenge is skills. Using AI effec-
tively requires more than knowing how to operate a tool. It
also means understanding risks, data, and responsibility.
Regulations also differ widely: Europe is more rule-based, the
U.S. moves faster on technology, and China is highly pragmat-
ic. For global companies like AVL, this creates very different
conditions for data use.
Wanker: Knowledge management is essential. The expertise
in people’s minds must be captured and made usable for AI
systems. Once that happens, knowledge becomes accessible
across teams and locations. This will fundamentally change
the engineering process and how value is created, as exper-
tise can then be applied at scale.
Bruhnke: Data quality is still a major challenge, especially for
training models in safety-relevant systems. But the goal is
clear: explainable and transparent AI that strengthens trust
and supports engineers in making better decisions.
Where is AI taking us next? What will vehicle development
look like in the coming years?
Bruhnke: We are moving toward self-learning vehicles that
improve continuously through data and feedback. They will
adapt their performance to real-world conditions and commu-
nicate with other systems to enhance safety and efficiency.
Wanker: The next big step is for AI to become invisible. It
will be embedded so deeply in our tools and workflows that
engineers will no longer notice it as a separate element. It will
simply be there, like electricity – powering everything we do.
At the same time, AI will democratize engineering knowledge,
making expertise accessible to many more people.
Poggenburg: AI will connect development, production, and
service even more closely. We will see systems that learn
from every stage of their lifecycle, from simulation and testing
to operation in the field. This creates a continuous improve-
ment loop that benefits both manufacturers and drivers.
Interview with
Stefan Bruhnke
EVP Sales and Business Development Engineering
Roland Wanker
VP Advanced Simulation Technologies
Jens Poggenburg
EVP Software Products, Emission and Services
Testing Solutions
2025
Interview with
Lukas Walter
COO of AVL Engineering
“Sometimes
You Just
Have to
Skip the
Hierarchy”
Lukas Walter has returned to
AVL, as a colleague and also as
part of the leadership team in the
role of Chief Operating Officer
Engineering. In this interview, he
talks about curiosity, responsibility,
and innovation as drivers of
change – and why sometimes
skipping hierarchy, or setting
a white tablecloth, reflects the
culture needed for the future of
mobility.
After several years at MAN, you returned to AVL. Did it feel
like a reunion or like a completely new company?
Both. Some structures and processes were familiar. But AVL
has developed enormously: today it is a global network with
strong affiliates and very independent management. That
international scope was new to me. At the same time, I saw
how much technological progress – from AI to new business
models – is embedded in daily life. Yet something of the “old
AVL” has remained, which I value.
You were brought back to advance transformation in the engi-
neering division. What attracted you to the role?
Everything: organization, processes, customer relationships,
culture. The range is particularly exciting: AVL covers all tech-
nologies, industries, and customers worldwide – that is unique.
And it comes with a clear expectation: We must be open to
transformation and stay curious. At MAN, I learned how trans-
formation works. Applying this knowledge here is truly reward-
ing. My approach builds on principles rather than super-precise
KPIs. Decisions should be made where the knowledge lies.
CORPORATE INSIGHTS
8 | 9
Transformation sounds big. How do you define it?
Transformation affects everything: organization, collaboration
with customers, culture, and technology. The key is believing
that change is possible – and actively shaping it rather than
just enduring it. Organizations must be self-adaptive, make
independent decisions, and engage with customers on equal
terms.
How have your first few days in the new role been?
Surprisingly hierarchical. All levels were sitting at the same
table during technical discussions. After six years in a com-
pany in which I had broken down hierarchies, this was a clear
contrast. I prefer when teams present their own solutions – it
saves time and avoids misunderstandings. The specialists
often have better information to make decisions than higher
levels. Sometimes you just have to skip the hierarchy to give
teams the freedom to make smart decisions.
The mobility industry is transforming. Where do you see the
greatest challenges?
The demand for mobility is rising worldwide. At the same
time, the energy supply is adapting. Therefore, in addition to
powertrains and vehicles, we are also working on energy sys-
tems around hydrogen and fuel cells. Advancing both mobility
and energy systems through innovation and a "cutting-edge"
approach must be our focus. We must not fall into the trap of
offering only commodity or interchangeable services.
Artificial intelligence is a hot topic. Will it replace people?
No. Domain know-how remains crucial. Our strength is com-
bining experience with AI. Over the years, we have gathered
data, simulated measured phenomena, and gained a deep
physical understanding. AI can do a lot, but without people
who understand what the results mean, there will be no prog-
ress.
How is collaboration with customers changing?
In the past, the focus was mainly on powertrains. Today, it is
on complete systems, vehicles, and software. This expands
the range of our stakeholders – from developers to CEOs. We
must be present at every level. Relationships are the core of
our business: It’s about long-term, trusting partnerships at all
levels. We have to work to ensure that our customers per-
ceive AVL as a whole. We can make this possible by inviting
customers to visit us. That is why I value things like the white
tablecloths in our canteen. They show how many customer
groups we are hosting, how much exchange takes place, how
guests perceive AVL as a company. This applies not only at
headquarters, but also at other locations – get the white cloth
on the table.
What is something most people do not know about you?
I often spend my free time in the forest, with protective gear
and a tractor, felling trees. It makes me feel rooted to the core
of the earth. I like the sustainability aspect, how the impact of
decisions is revealed over the long term. I also value encoun-
ters without staging – direct, honest, at eye level. You can
argue passionately and still remain respectful. That is what
good collaboration is about.
What drives you personally?
I am motivated by moving things forward – from small im-
provements to major shifts. And by friendly encounters and
good conversations. Those are just as valuable to me as big
successes. Of course, my private environment is also crucial.
Without that balance, I would not be able to generate the
energy for work.
What is your biggest goal for AVL?
Innovation, differentiation, sustainability. For AVL to remain
strong for decades to come. We want everyone to take re-
sponsibility, stay curious – and sometimes skip the hierarchy.
What do you take from your career so far?
At MAN, I learned how much is possible in transformation
when you stretch boundaries. One colleague even switched
from diesel development to battery development five years
before retirement – and said those last years were the best
of his 40-year career. That is real engineering: staying curious,
pushing limits, constantly learning, adapting, and embracing
new technologies. This mindset is essential for success in our
industry – and for motivation.
A final piece of advice for the team?
Be courageous. Take responsibility, make mistakes, and learn
from them. Stay curious, question things, think outside the
box. And never forget – friendliness and openness make work
more enjoyable for everyone.
“Transformation is not something you
endure – it is something you shape,
every day, at every level.”
2025
Located in the city of Steyr, Austria, the AVL Tech Center Steyr is
a state-of-the-art hub for the development and testing of next-
generation commercial vehicles. Spanning approximately 15,000
m² and staffed by around 100 experts, the facility combines
engineering excellence with cutting-edge testing infrastructure –
shaping the future of sustainable, intelligent mobility.
AVL Tech Center Steyr
Driving the Future
of Commercial
Mobility
Engineering and Testing Under One Roof
From initial concept and simulation to full-vehicle validation,
AVL delivers the entire development cycle in a single loca-
tion – supported by the strength and expertise of AVL’s global
engineering network. This close integration enables seamless
collaboration, faster iteration loops, and highly efficient project
execution.
Six high-performance testbeds allow comprehensive testing
of powertrains and entire vehicles up to 14 meters in length.
With capabilities of up to 125,000 Nm wheel torque, 800
kW wheel power, and 1,600 kW transmission input, even the
most demanding applications can be validated under realistic
conditions. The facility is hydrogen-ready, enabling advanced
fuel cell and hydrogen propulsion system testing to drive clean
mobility innovations. Specialized capabilities – such as one of
the world’s first brake emission testing systems for heavy-duty
vehicles – support compliance with upcoming Euro 7 regula-
tions.
A dedicated 5,000 m² off-road proving ground, including
hill gradients of 8 % and 12 %, ensures real-world validation
of heavy-duty and off-road vehicles. Prototype and general
commercial vehicle development is supported by flexible
workshops, sheltered assembly zones, and integrated fast-
charging infrastructure – offering end-to-end support across
the development cycle.
CORPORATE INSIGHTS
10 | 11
Commitment to Sustainability
Beyond its technical capabilities, the Tech Center Steyr is a
showcase of AVL’s sustainability strategy. At its heart is a
holistic energy and heat recovery system, developed together
with APESS® GmbH and Metaplan Energietechnik GmbH. The
concept enables the entire site – including offices, workshops,
and testbeds – to operate completely without fossil fuels (of
course, with the exception of the fuel required to operate an
ICE unit under test).
Three custom-built heat pumps, intelligent hydraulic circuits,
and a compound-loop recovery system enable simultaneous
generation of heating and cooling energy. Waste heat from
the testbeds is fed directly into the hot water system, ensuring
maximum utilization. The intelligent control unit dynamically
selects energy sources to optimize efficiency. Real-world data
confirm the system’s outstanding performance: a COP of
5.89 during the heating season and 41.2 % lower electricity
consumption compared to standard heat pumps.
This pioneering achievement was honored with the ATZlive
Sustainability Award 2025 in the "Mobility Concepts - Business
Models" category, underlining AVL’s role as a benchmark-setter
for sustainable facility design.
Fuel Cell Technology Demonstrator Truck
A highlight of the opening was the first public demonstration
of AVL’s Fuel Cell Demonstrator Truck at the Vienna Motor
Symposium 2025. Hydrogen-based fuel cell systems are wide-
ly regarded as a key technology for achieving clean, efficient
long-haul transportation. The demonstrator, which also re-
ceived a 2025 ATZlive congress award (category: “Technology
- Complete Vehicle”), integrates AVL’s proprietary core tech-
nologies – from fuel cell stacks and system architecture to
advanced thermal management. Features include a high-pow-
er fuel cell system with leading efficiency, a Digital Twin for
predictive fleet operation, and no-flame-out battery technology
for enhanced safety. While not intended for series production,
the truck is a near-market prototype, offering a clear vision of
how zero-emission heavy-duty mobility can become reality.
Automation Solution for Off-Road Vehicles
Alongside fuel cell innovation, AVL is also driving autonomy in
challenging environments. In cooperation with ARTI-Robots
initiated by AVL Creators, AVL has developed a generic auto-
mation solution for off-road vehicles.
Designed for flexibility and scalability, the system can be
integrated into new platforms or retrofitted into existing fleets.
It combines localization, navigation, task planning, teleopera-
tion, and comprehensive safety features in a single package.
Multimodal sensor fusion ensures reliability even under harsh
conditions.
This technology has already been implemented in the AVL
Demonstrator Tractor, where it showcases real-world potential
for agriculture and other off-road applications. By addressing
both labor shortages and efficiency demands, AVL helps in-
dustries such as farming and construction meet the challeng-
es of tomorrow.
Shaping Tomorrow’s Mobility
With its unique combination of engineering expertise, ad-
vanced testing capabilities, and award-winning sustainability
measures, AVL Tech Center Steyr is more than a facility – it
is a driving force behind the transformation of commercial
mobility.
The integration of holistic energy management, zero-emission
propulsion, and intelligent automation sends a clear message:
the road to climate-neutral, efficient, and intelligent transporta-
tion requires not only vision but also infrastructure, innovation,
and the courage to lead by example.
AVL Tech
Center Steyr
• Opened April 2025 in Steyr, Austria
• 15,000 m² hub with around 100 experts
• 6 high-performance testbeds – hydrogen-ready,
up to 14 m vehicles
• Brake emission testing system for Euro 7 compliance
• 5,000 m² proving ground with 8 % and 12 % gradients
• 100 % fossil-free energy concept, COP 5.89
• Innovation showcase: Fuel Cell Demo Truck and Off-
Road Automation
• Award-winning: ATZlive Sustainability Award 2025
Guests of honor, includ-
ing AVL Chairman and
CEO Prof. Helmut List
(fourth from left), cut the
ribbon at the opening
of the AVL Tech Center
in Steyr.
2025
A Milestone in European Testing Infrastructure
On May 14, 2025, AVL ZalaZONE inaugurated the new high-
speed oval track at its ZalaZONE proving ground in Zalae-
gerszeg, Hungary. The opening marks another important step
in the expansion of one of the most modern proving grounds
in Europe.
The track is approximately 4,450 meters long and consists of
two straight sections of 950 meters each and two parabolic
curves with a radius of 350 meters. With four lanes (each 3.75
meters wide) and a crown width of 22.5 meters, the facility
CORPORATE INSIGHTS
With the addition of a high-speed oval track, AVL ZalaZONE now
offers one of the most advanced testing environments in Europe.
Built with extreme precision and banking of up to 47 degrees, the
track enables new levels of vehicle testing at speeds exceeding
270 km/h. With the official opening of the new facility by Prof.
List, AVL is strengthening its position as a leading provider of
testing for the mobility of the future.
AVL ZalaZONE Opens New High-Speed Oval
Full Speed Ahead
at ZalaZONE
enables high-speed testing of various vehicle types, including
passenger cars and commercial vehicles.
Built for Stability – and Speed
A key feature of the oval is its neutral driving zone, allowing
speeds between 21 and 180 km/h without lateral accelera-
tion. In the outermost lane, vehicles can reach speeds of up
to 270 km/h in the curves and even higher on the straights,
depending on vehicle performance.
12 | 13
“With the new high-
speed oval track, we
are strengthening
AVL ZalaZONE’s
position as a leading
proving ground in
Europe.”
The track complies with international standards, including
UNECE R79 and ISO 15037-1, and was built using 3D-con-
trolled paving technology and precision geometry. There are
only two machine chains in the world capable of producing
asphalt surfaces with this level of banking and accuracy.
More Than Just an Oval
AVL ZalaZONE is part of a comprehensive testing ecosystem
spanning 250 hectares. The facility includes 13 dedicated
modules for testing autonomous functions, driving dynam-
ics, and durability – such as smart city environment, ADAS/
AD zone, off-road section, wet handling, and NVH surface.
The modules are designed for all types of vehicles, including
heavy-duty trucks and buses with axle loads of up to 16 metric
tons.
On-site services include fully equipped workshops, hydrogen
and EV charging stations, ADAS simulation and data labs, ho-
mologation support, and certified test driver training. Testing
is possible year-round under highly controlled and repeatable
conditions.
A Strategic Platform for AVL and the Industry
AVL ZalaZONE is already being used by more than 50 inter-
national manufacturers and suppliers, with further growth
expected following the oval’s addition. Thanks to its modular
infrastructure and seamless integration of physical and virtual
testing, ZalaZONE supports faster validation workflows and
helps reduce time to market. Whether for electric vehicles,
advanced driver assistance, automated driving, or high-load
durability testing, the oval extends the capabilities of an al-
ready state-of-the-art facility.
A Track You Can Feel
The opening day offered guests an unforgettable glimpse
into the full potential of the new facility. Professional drivers
took visitors on rides in high-performance vehicles, reaching
speeds of over 200 km/h in the steeply banked curves. Over
the course of two laps, guests experienced firsthand what it
means to test at the limits of stability and control.
In addition, special demonstrations showcased steering and
pedal robots executing dynamic maneuvers – such as double
lane changes – on the adjacent dynamic platform. During the
“Fun Drive” program, guests had the opportunity to explore the
handling courses alongside experienced instructors, combin-
ing technical insight with adrenaline-filled driving.
Let the Testing Begin
The high-speed oval marks a new chapter for AVL ZalaZONE
and sends a strong signal to the global mobility industry. As
vehicle systems grow more complex, testing infrastructure
must not only keep pace – it must set the pace. At ZalaZONE,
AVL combines engineering expertise, simulation integration,
and world-class facilities in a central location for future mobil-
ity testing.
• Total area: 250 hectares
• Modules: 13 – including Smart City Zone,
ADAS/AD, off-road, dynamic platform
• Vehicle types: passenger cars, trucks, buses
(axle loads up to 16 metric tons)
• Standards: UNECE R79, ISO 15037-1
• Certifications: ISO 27001, TISAX
• On-site services: workshops, charging/refueling,
engineering, test driver service, driver training
The New High-Speed Oval
• 4,450 m total length
• Two straights: 950 m each
• Two curves: radius 350 m
• Banking: up to 47 degrees
• Neutral driving: 21–180 km/h
• Maximum cornering speed: up to 270 km/h
AVL ZalaZONE
at a Glance
Zoltán Hamar
Managing Director of
AVL ZalaZONE
2025
HOME OF INNOVATION
14 | 15
At AVL, innovation has always been
more than the pursuit of progress; it’s
our way of shaping the future. Across
all fields of technology, we turn ideas
into real-world solutions that make
mobility cleaner, smarter, and more
connected.
2025
Green Hydrogen as a Key to the Energy Transition
Green hydrogen is regarded as a key energy carrier of the
future. It enables the storage of renewable energy, serves as a
carbon-free feedstock in industrial processes, and can replace
fossil fuels in mobility and heavy-duty transport. At the heart
of this transformation lies electrolysis, which splits water into
hydrogen and oxygen. Among the available technologies,
proton exchange membrane (PEM) electrolysis is increasingly
in focus. It combines high efficiency, dynamic operation, and
compact design – the exact features required for integration
into renewable energy systems.
With its first proprietary PEM electrolyzer stack, AVL marks
a significant milestone in hydrogen technology. Developed,
built, and tested within just twelve months, the AEE 1 already
surpasses international efficiency targets. It demonstrates how
AVL successfully transfers its automotive know-how into the
energy sector.
Hydrogen Innovation
Made in Graz and
Vancouver
AVL’s First In-House PEM Electrolyzer Stack
Technology Environment and Market Demand
Currently, alkaline electrolyzers (AEL) dominate the market.
They are cost-effective, but comparatively slow and less
efficient. PEM electrolyzers, on the other hand, can respond
rapidly to fluctuating power from wind and solar energy,
operate at higher current densities, and produce high-purity
hydrogen. Global demand is therefore rising for high-
performance PEM stacks that enable the scale-up of green
hydrogen. AVL has positioned itself early on to address this
need.
16 | 17
HOME OF INNOVATION
ENERGY AND SUSTAINABILITY
The Innovation: AEE 1
In 2024, AVL took a decisive step: with its first proprietary
PEM electrolyzer stack – designated AEE 1 – a new level
of technology excellence was established. Developed,
manufactured, and tested entirely in-house within only twelve
months, the stack stands out not only for its efficiency, but
also for several technological features that set it apart from
existing solutions:
• Differential pressure operation: AEE 1 operates reliably at
30 bar. This reduces the need for additional compressors
and simplifies direct integration into industrial processes.
• Optimized water and gas management: Uniform
distribution across all cells ensures low pressure losses
and minimizes degradation – critical for long service life.
• Material and design innovations: Tailored bipolar plates
and catalyst layers enhance robustness and enable high
current densities, even under dynamic operation with
renewable energy sources.
Development Process and Core Competencies
The stack architecture builds on AVL’s profound understanding
of hydrogen technology and its long-standing experience
with automotive fuel cell stacks. Proven principles from
high-volume manufacturing – such as precise sealing
concepts and minimized contact resistance – were directly
transferred to the electrolyzer design. Another decisive factor
was AVL’s methodology of safeguarding designs through
virtual simulation and co-simulation with Digital Twins,
which shortened iteration loops significantly, while ensuring
maximum precision and quality.
Customer Benefits and Market Impact
The benefits for customers are clear: AEE 1 enables reduced
development costs and shorter time to market. Beyond
providing the technology, AVL supports customers with
simulation, testing, and training. A current example is a
project with a Chinese partner to develop a 2.5 MW stack
based on the AEE 1 design, demonstrating that the solution is
immediately transferable to industrial scale.
With its first PEM stack developed in-house, AVL underscores
its innovative strength in energy technology. AEE 1 exemplifies
how expertise from the automotive industry can be
successfully applied to the challenges of the energy transition.
It represents AVL’s commitment to actively shaping the path to
a climate-neutral future.
AEE 1 PEM
Electrolyzer Stack
• Developed in just 12 months
• Efficiency: 71 % (LHV) > exceed-
ing DOE 2026 target (69 %)
• Energy consumption:
47 kWh/kg H2
• Operation at 30 bar differential
pressure
• Active cell area: 300 cm²
• Foundation: automotive fuel cell
engineering know-how
• Reference project: 2.5 MW PEM
stack with Chinese partner in
development
“The AEE 1 is a
technological
breakthrough for
scalable, efficient
PEM electrolysis,
marking AVL’s entry
into industrial stack
development.”
JÜRGEN RECHBERGER
Head of Business Unit Fuel Cell & Energy
2025
HOME OF INNOVATION
ENERGY AND SUSTAINABILITY
Revolutionizing Hydrogen
Technology Testing Together
HyCentA and AVL
HyCentA and AVL have joined forces in the COMET program (Competence
Centers for Excellent Technologies) to revolutionize the testing and
validation of hydrogen technologies. This strategic collaboration unites
cutting‑edge research with proven engineering expertise, paving the way
for safer, more efficient, and longer‑lasting hydrogen applications.
develop groundbreaking solutions that will support the transi-
tion to a hydrogen‑powered future,” says Dr. Alexander Trattner,
CEO & Research Director at HyCentA. AVL shares this com-
mitment: “With our experience in simulation and testing, AVL
is excited to work with HyCentA to drive hydrogen technology
advancements. Our joint efforts will lead to more efficient and
sustainable hydrogen applications worldwide,” adds Helmut
Iancu, Global Business Segment Manager at AVL.
Building the Next Generation of Testing Technologies
Through its integrated approach, ReMET is building the next
generation of measurement and testing technologies for
hydrogen applications – from containerized electrolyzer test-
beds with multi‑megawatt capacity to advanced diagnostic
and simulation environments. By accelerating development
cycles and improving system reliability, the project is laying the
foundation for faster commercialization of hydrogen technolo-
gies, strengthening Austria’s role as a global innovation leader
in the hydrogen economy.
aunched in 2023, the COMET project ReMET (Revolution-
ary Measurement and Testing Technologies for Hydro-
gen Applications) aims to set new industry benchmarks
for performance, safety, and durability in hydrogen systems.
Funded by the COMET program, it focuses on electrolyzers,
fuel cells, and hydrogen storage solutions, addressing the
most critical challenges in their development and commercial-
ization.
From Testing Methods to International Standards
The hydrogen economy demands systems that are safe,
efficient, and long‑lasting. Achieving this requires precise
testing methods, robust measurement technology, and clear
international standards. ReMET addresses all three. A major
focus of the strategic cooperation is on new test methods
for electrolyzers, including advanced analysis of degradation
and operating conditions to improve durability. This is com-
plemented by precise measurement technology for hydrogen
systems, enabling cost‑effective monitoring while ensuring
operational safety.
Innovation Across the Hydrogen Value Chain
The project also targets material compatibility studies, assess-
ing long‑term stability and permeability to ensure safe applica-
tions. Diagnostic tools for online health monitoring will allow
early detection of degradation mechanisms and help optimize
fuel cell lifetime. In parallel, simulation models and AI‑driven
testing frameworks will support predictive maintenance and
performance optimization. Standardization and certification
activities within ReMET aim to pave the way for the safe and
widespread implementation of hydrogen technologies.
A Shared Commitment to Progress
“This partnership marks a major step forward in hydrogen
research and testing. Combining our expertise enables us to
HyCentA stands for Hydrogen Research Center Austria.
Founded in 2005, HyCentA Research GmbH is Austria’s
leading non-university research institute for hydrogen
technologies. HyCentA operates within the COMET program
(Competence Centers for Excellent Technologies), which
receives funding from the BMIMI (Federal Ministry for
Innovation, Mobility, and Infrastructure) and the BMWET
(Federal Ministry for Economy, Energy, and Tourism), as well
as the co-financing federal provinces of Styria, Upper Austria,
Tyrol, and Vienna. The COMET program is managed by the
Austrian Research Promotion Agency (FFG).
18 | 19
First Time Right
Electrolyzer development does not allow for endless prototype loops. Early
application of multiphysics modeling and simulation at the system level
is becoming increasingly important. With its advanced solutions, AVL not
only speeds up development and saves costs – it also unlocks the potential
to design better, more robust electrolyzers from day one.
interactions between stack, balance of plant (BoP) compo-
nents, control strategies, and dynamic load conditions – espe-
cially in combination with renewable energy sources.
AVL’s scalable simulation approach allows engineers to test
different materials, geometries, and operating scenarios
virtually – not only to boost efficiency, but to identify potential
failure modes early on. With growing emphasis on total cost
of ownership and uptime, the ability to simulate and optimize
lifetime has become a decisive differentiator.
Digital Twins for Durability
The long-term goal is a real-time Digital Twin of the electro-
lyzer system that monitors operating conditions continuously
and predicts degradation in response to fluctuating loads and
ambient influences. This would allow predictive maintenance
and adaptive control strategies that extend stack lifetime and
lower the levelized cost of hydrogen.
AVL is already laying the foundation for this vision. By com-
bining data-driven models with physics-based simulation, and
calibrating these models against experimental results, highly
accurate lifetime prediction is now within reach. For a tech-
nology sector defined by long investment cycles and steep
learning curves, this is a game changer.
Unlocking Lifetime Potential Through Simulation
As global momentum around green hydrogen continues to
increase, electrolyzer technology is stepping into the spot-
light. Whether based on proton exchange membrane (PEM),
anion exchange membrane (AEM), alkaline, or solid oxide (SO)
technology, all electrolyzer systems face similar development
challenges: efficiency, cost, scalability, and – most critically –
lifetime.
Traditional hardware-based validation methods reach their
limits when systems must meet lifetime requirements of up to
100,000 operating hours. This is why simulation is no longer
a supporting tool – it is a strategic enabler. AVL’s simulation
platforms AVL FIRE™ M and AVL CRUISE™ M provide detailed
insights into flow dynamics, thermal effects, and electrochem-
ical processes. These insights form the basis for understand-
ing degradation mechanisms and simulating component
longevity – long before a physical prototype is built.
From Stack to System – and Back Again
Stack performance alone does not determine overall efficiency
or durability. Design choices such as membrane thickness or
system pressure may appear beneficial at cell level but might
compromise overall system performance. Simulation enables
developers to evaluate the entire system, accounting for the
How Simulation Drives
Electrolyzer Efficiency and
Lifetime from Day One
2025
From Regulation to
Real-World Value
Digital battery passports (DBP) will become mandatory in the EU from
2027 – but they are much more than a compliance tool. By enabling
transparency, traceability, and circularity, they will shape the future of
sustainable mobility. AVL offers a turnkey solution that helps customers
master the challenges and turn regulation into opportunity.
attery value chains are under close scrutiny: from raw
material sourcing and carbon footprint to second life
and recycling. Companies must prove sustainabili-
ty, ensure data integrity, and comply with rising regulatory
demands. Digital battery passports create a standardized
Digital Twin of the battery, enabling lifecycle transparency and
circular economy models.
Complex Path to Compliance
While the benefits of DBPs are clear, the road to implementa-
tion, however, is demanding. Harmonized data formats across
fragmented supply chains are still evolving. Confidentiality
raises concerns over intellectual property protection. Techni-
cally, a DBP requires integration of battery management sys-
tems (BMS), secure cloud platforms, and strong cybersecurity.
Fixed IT and compliance costs pose a significant barrier to
DBP adoption. Ensuring data accuracy through standardized
audits and cooperation across the value chain – even among
competitors – is essential.
A Secure End-to-End Platform
AVL addresses these challenges with a modular, compli-
ance-ready platform. The AVL Digital Battery Passport inte-
grates data from BMS and supply chain sources into a secure,
cloud-based architecture. Built-in interoperability ensures
alignment with EU and international frameworks, while dash-
boards and user-friendly interfaces make information accessi-
ble. Developed at AVL’s Battery Innovation Center, the solution
is validated in real testing environments. In partnership with
Microsoft, AVL provides certified cloud infrastructure, ad-
vanced security, and data notarization to protect data integrity.
Complementary consulting and integration services further
reduce complexity.
Early Readiness, Tangible Benefits
AVL’s turnkey approach accelerates regulatory readiness.
Customers gain early compliance with the 2027 mandate,
improved ESG reporting, as well as transparency on carbon
footprint and raw material sourcing. The scalable design
makes the system accessible to both OEMs and SMEs, avoid-
ing exclusion due to cost or complexity.
Differentiators That Build Trust
AVL combines lifecycle expertise with proven digital ecosys-
tem know-how. Participation in initiatives such as Catena-X
ensures standard alignment. A strong focus on robust data
governance builds the trust needed to share sensitive infor-
mation across global supply chains. The solution is already de-
signed for future digital product passport (DPP) requirements,
including vehicle passports.
From Obligation to Opportunity
The countdown to 2027 is underway. Early adoption avoids
last-minute risks and positions companies as leaders in sus-
tainable mobility. More than a regulatory obligation, a DBP is
an enabler for circular business models and a key step toward
climate-neutral transport. With AVL’s solution, compliance
becomes competitive advantage.
AVL Digital Battery Passport
20 | 21