Seamless collaboration in lead-development driving electrolysis innovation
“I came to Bosch through the electrolysis project”, Markus Winklberger, development engineer in the field of simulation explains. Markus and his colleague Bernhard Beißmann, leader of the design team, work closely together to further develop Hybrion PEM electrolysis stacks at Bosch. They first met during a brainstorming session on further improving the framework concept of the electrolysis stacks. Both know, collaboration is key for the success of their work.
Bernhard and Markus' Story
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Design and simulation hand in hand
The development process is a highly creative but also iterative one. Regular coordination and check-ins of the design and the simulation team are crucial. Bernhard and his design team, for example, generate 3D models which are directly used by Markus and the simulation team. These models serve as the basis for comprehensive calculations, the analysis of different load and stress scenarios, and the verification of compliance with applicable standards and legal requirements. Markus points out: ”working in the electrolysis field is quite different from working in the process industry. There is still very little standardization in this specialized market. At this very moment, we are helping to shape future standardizations.”
Testing is not a can – it’s a must
A climate-friendly hydrogen economy relies not only on technology but also on the ability to reliably test performance and quality. Standardized testing methods and advanced test benches form the foundation to produce Hybrion PEM electrolysis stacks efficiently, safely, and with high quality. Precise measurements and systematic testing generate data insights – and consequently lead to further development of the Hybrion PEM electrolysis stacks. At the same time, on the testing side, we at Bosch actively contribute to the development of new standards and with that ensure test results remain comparable within the industry.
Material matters: A closer look on PEM electrolysis
Material science plays a central role in optimizing the operational lifetime of electrolysis stacks. As materials degrade over time, understanding the underlying processes is crucial for developing effective countermeasures. In Linz as well as in Tilburg these so called “aging tests” are conducted. Wear is artificially induced in order to simulate long-term conditions and observe degradation patterns. By studying how materials change under stress, it becomes possible to design strategies to slow down or prevent deterioration. This proactive approach ensures that Hybrion stacks remain efficient and reliable throughout their service life.
Optimizing PEM electrolysis stacks isn't just about collecting as much data as possible – it's about identifying the values that truly impact system performance.
What is PEM again?
PEM stands for Proton Exchange Membrane electrolysis, a process that splits water into hydrogen and oxygen using electricity. At the anode, water molecules are decomposed, releasing oxygen, protons, and electrons. The protons migrate through the membrane to the cathode, where they combine with electrons to form hydrogen gas. This simple yet elegant process underpins the generation of green hydrogen.
At its core, PEM electrolysis involves managing the flow of gases and water on either side of the catalyst-coated membrane (CCM) while ensuring electron transport.
These processes are inherently contradictory: electron conduction requires solid materials like metals, whereas gas and water transport are best achieved through porous, less dense structures. The solution lies in using porous materials on both sides of the CCM, striking a balance between conductivity and permeability. This delicate balance is essential for maintaining optimal reaction conditions and system longevity.
Looking ahead
We have already developed a PEM electrolysis stack with an output of 1.25 MW, capable of producing around 22,9 kg of hydrogen per hour — enough to power a 40-ton truck for 250 to 300 kilometers. But the journey of regeneratively produced hydrogen is just beginning. Together with our colleagues in Tilburg, Linz and Bamberg, we will continue to advance knowledge and innovation around electrolysis technology. Because data-driven insights always lead us to better products – and that's at the core of Bosch's value proposition.
