Fuel cell systems are manufactured in two steps based on the individual fuel cells. They are first assembled into a fuel cell stack. The next step involves fitting all the other components to produce a complete fuel cell system.
Stacking the fuel cells is essentially a fully automated process. Once the components are inspected for damage, the stack is compressed and placed in a housing. The stack housing is manufactured in the light metal foundry at BMW Group Plant Landshut using a sand casting technique. For this, molten aluminium is poured into a mould made from compacted sand mixed with resin in a process specially designed for this small-series vehicle.
The pressure plate, which delivers Hydrogen and oxygen to the fuel cell stack, is made from cast plastic parts and light-alloy castings, also from the Landshut plant. The pressure plate forms a gas-tight and water-tight seal around the stack housing.
The final assembly of the fuel cell stacks includes a voltage test and extensive chemical reaction testing within the cells. Finally, all the components are fitted together in the assembly area to produce the complete system.
In combination with a highly integrated drive unit using fifth-generation BMW eDrive technology (the electric motor, transmission and power electronics are grouped in a compact housing) at the rear axle and a powerful battery with lithium-ion technology developed especially for this vehicle, the powertrain channels maximum output of 295kW / 401 hp onto the road. In coasting overrun and braking phases, the motor also serves as a generator, feeding energy back into a power battery.
