General Motors and Honda have begun volume production of hydrogen fuel cell systems at their joint venture facility, Fuel Cell System Manufacturing (FCSM), in Brownstown, Michigan. Established in 2017 through an $85 million investment, the 70,000-square-foot plant is the first large-scale manufacturing joint venture dedicated to commercialized hydrogen fuel cells. The milestone follows more than a decade of collaboration between the automakers, which began in 2013 to develop a next-generation fuel cell system.
Honda’s research into hydrogen technologies spans over 30 years, and the new system represents a significant leap in durability and efficiency. By incorporating corrosion-resistant materials and improving low-temperature performance, the companies have doubled the durability compared to the 2019 Honda Clarity Fuel Cell. The manufacturing process has been refined to reduce costs by one-third relative to the previous system, achieved through economies of scale, streamlined auxiliary equipment, common sourcing, and reduced use of precious metals.
“This is a historic day for the industry as GM and Honda are the first full fuel cell system manufacturing joint venture to begin volume production of fuel cells for transportation and beyond,” said FCSM president Suheb Haq. “We begin the process with raw materials for membrane and electrode all the way through completed systems. Ongoing investment and commitment by both companies is driving our success at FCSM. This commitment aligns with our mission of making high quality, durable, and affordable hydrogen fuel cell systems for a wide range of applications and customers.”
FCSM Vice President Tetsuo Suzuki emphasized the integration of both companies’ strengths. “We integrated the strengths of Honda and GM to create the most capable production system at this joint venture. We brought a mass production mindset with attention to detail and a focus on high quality, and now we are ready to meet the needs of the customers for the future applications of fuel cell technology and the beginning of the hydrogen era.”
The facility employs advanced automation in membrane-electrode assembly and fuel cell stack assembly, introducing several first-of-their-kind production methods. Jay Joseph, American Honda Motor Co.’s vice president of sustainability and business development, stated, “Our new fuel cell system is at the core of Honda hydrogen technology and our strategy to expand the range of applications that use hydrogen to facilitate the decarbonization of society. This is not simply a choice between battery electric or hydrogen fuel cell technology, but selecting the right energy source, in the right place, for the right purpose, to achieve carbon neutrality as quickly and efficiently as possible.”
The first Honda vehicle to use the new system will be an FCEV variant of the CR-V, introduced in 2022, with launches planned for North America and Japan this year. Both companies see applications for the technology in zero-emissions propulsion and energy management beyond passenger vehicles.
Parallel to these developments, the prospect of roadable aircraft—commonly called flying cars—is advancing toward commercial reality. U.S. firms Samson Sky and Alef, along with European manufacturers Pal-V and Klein, are preparing production models. Samson Sky’s Switchblade, a three-wheel, street-legal flying sports car, completed its maiden flight in November 2023. Powered by a hybrid electric system running on unleaded automotive gasoline, it can be refueled at standard gas stations. The vehicle’s wings deploy and tail extends in under three minutes, and it offers a 500-mile flight range per tank.
More than 2,300 reservations have been placed from buyers in 57 countries and every U.S. state. Samson Sky contributed to the drafting of New Hampshire’s 2020 “Jetson Bill,” the first state law enabling road registration of aircraft that can also operate on highways. The legislation specifies that such vehicles must follow standard traffic laws while driving and may only take off or land on public roads in emergencies.
Building on this precedent, Samson Sky’s legislative analyst Russell Bousfield confirmed that bills are being prepared in eight additional states for introduction this year. The New Hampshire framework aligns with FAA certification processes, allowing owners to register their vehicles for road use at the DMV. As outlined by the company, operation involves driving from a garage to a nearby airport, converting to flight mode, flying to the destination’s closest airport, then returning to road mode for the final leg. The Switchblade seats two, with space for luggage, and is designed to integrate seamlessly into existing transportation infrastructure.