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MAHLE Powertrain Enhances Hydrogen Testing Capabilities In Northampton
MAHLE Powertrain, a subsidiary of the MAHLE Group, is enhancing its Northampton facility to include hydrogen powertrain testing. This expansion will support both light and heavy-duty applications. The facility can hold two tube-trailers on-site, enabling a near-continuous hydrogen supply through rapid switch-over functionality.
The upgraded engine dynamometers at the Northampton site now boast a 900kW and 4,000Nm nominal capacity. This enhancement positions the centre to meet the rising demand for hydrogen powertrain development. It also supports rigorous testing of heavy-duty engines with increased weight and torque characteristics.
Simon Reader, Director - Global Engineering Services at MAHLE Powertrain, stated, "Off-highway, heavy-duty and marine sectors are increasingly looking to hydrogen combustion engines as a way of decarbonizing their emissions in areas where electrification isn’t suitable."
The facility is already engaged in developing hydrogen fuel cell systems and hydrogen combustion engines. It also tests hydrogen-fuelled vehicles. Soon, it will start working on an H2-ICE concept that converts existing heavy-duty diesel engines to hydrogen combustion. This approach leverages existing infrastructure to speed up the transition towards net-zero mobility.
The facility’s supply side adheres strictly to BCGA guidelines for storing and handling hydrogen. Each test cell features a unique system designed by MAHLE Powertrain for monitoring and safely handling potential gas escapes.
Vehicle Development Centre
MAHLE Powertrain’s Northampton site also includes a Vehicle Development Centre. This centre supports testing next-generation electric and hydrogen-fuelled vehicles. The test chambers can accommodate both two- and four-wheel-drive vehicles at speeds up to 155mph. Climatic conditions from -40°C to +60°C can be simulated with humidity ranging from 10% to 80%.
The site also includes a Battery Development Centre with its own substation and dedicated National Grid connection. It can test battery packs up to 1MW with full fire protection in case of thermal runaway. A prototype and low-volume battery build area supports end-to-end battery development for customers.
Global Presence
MAHLE Powertrain operates independently of the main group when choosing components or technologies. It has six technical centres located in the UK, Germany, USA, and China with approximately 400 employees globally.
The company has expertise in developing engines adapted to run on renewable alcohol fuels like methanol. Additionally, its Stuttgart facility replicates the Battery Development Centre's capabilities for European customers.
MAHLE is an international development partner for the automotive industry, serving both passenger car and commercial vehicle sectors since 1920. The company focuses on climate-neutral mobility through electrification, thermal management, fuel cells, and efficient combustion engines running on hydrogen or synthetic fuels.
Today, MAHLE components are found in one out of every two vehicles worldwide. In 2023, MAHLE generated sales just under EUR 13 billion with around 72,500 employees across 148 production locations and 11 major research centres in 29 countries.
This expansion reflects strong customer demand for hydrogen powertrain testing capabilities. It equips MAHLE Powertrain’s test cells with dedicated hydrogen supplies for rigorous testing of even the most heavy-duty engines.
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