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