Hyundai Motor unveils new NEXO FCEV; targets more than 700 km (435 miles) of range from a five-minute charge
03 April 2025
Hyundai Motor Company introduced the all-new NEXO fuel cell electric vehicle (FCEV) mid-size SUV at a global launch event at the Seoul Mobility Show in Korea. The second-generation NEXO reflects Hyundai Motor’s leadership in hydrogen mobility and 27 years of fuel cell technology experience. This new model also underscores the company’s commitment to a diversified vehicle electrification strategy, which includes not only battery electric vehicles (BEVs) and hybrids, but also FCEVs, offering wider consumer choice.
Based on the INITIUM concept unveiled in October 2024, the all-new NEXO embodies Hyundai Motor’s new ‘Art of Steel’ design language, reflecting the inherent strength and natural formability of the material.
The all-new NEXO features significant powertrain advancements centered around the fuel cell (FC) and power electronics (PE) systems, which have been enhanced to improve power output and performance.
A new motor system complements these enhancements, increasing the PE system’s power output and battery capacity. As a result, the total output has been elevated from 135 kW to 190 kW, while the battery’s output has doubled from 40 kW to 80 kW. These improvements contribute to a faster 0-100 km/h acceleration time of 7.8 seconds compared with 9.2 seconds for the previous NEXO, ensuring excellent acceleration and smooth overtaking capability.
The hydrogen fuel cell stack now delivers maximum gross power of 110 kW, a 16% increase, while the new electric motor provides up to 150 kW. The FC stack also features improved low-temperature operability and durability enhancements, including to the membrane, and a uniform cell performance structure. The Wake Up stack anti-freezing function and other system optimizations enhance low-temperature drivability and ease of starting year-round.
Additionally, the all-new NEXO offers increased fuel storage capacity without compromising cabin space. The system’s all-electric range (AER) competitiveness is secured through enhanced fuel efficiency, as well as an increased hydrogen tank capacity—which now stands at 6.69 kg, up from 6.33 kg in the previous-generation NEXO—and increased hydrogen storage density.
Aerodynamic improvements, including underbody optimizations and airflow management enhancements, reduce drag and improve efficiency. The vehicle’s advanced noise, vibration and harshness (NVH) performance is bolstered by technologies such as Active Noise Control-Road (ANC-R) noise cancelling and sound-absorbing tires, improving vehicle refinement, especially during acceleration and on rough roads. To enhance usability further, European-specification models of the all-new NEXO offer towing capability of up to 1,000 kg.
The NEXO’s e-Handling system further enhances driving performance through motor torque control for improved handling. By adjusting motor output, the system optimizes grip, boosting steering response and stability.
NEXO utilizes a Smart Regenerative System (SRS) to enhance driving convenience by automatically adjusting regenerative braking based on navigation data and distance to vehicles ahead. Available globally, this system uses extended map information to adapt to road conditions, such as speed cameras, turns, and speed humps. It reduces driver intervention by automatically managing deceleration during coasting, with adjustable vehicle distance settings.
Much like Hyundai Motor’s BEVs, the NEXO features a vehicle-to-load (V2L) function that provides versatile power solutions both inside and outside the vehicle. Inside, an outlet on the center console allows users to plug in home electronic devices and appliances, powered by the vehicle’s high-voltage battery. Similarly, the exterior V2L function enables the use of electronic devices without the need for a separate V2L connector or adapter, offering direct plug-in capability.
The vehicle features a multi-skeleton structure and up to nine airbags for the protection of passengers and the NEXO’s hydrogen tank. It is also equipped with the latest Advanced Driver Assistance System (ADAS) technologies for collision prevention.
NEXO is constructed using hot stamping and high-strength materials to enhance body rigidity and ensure strong passive safety through effective passenger room protection. It features top-grade collision performance across all body regions and has been designed to absorb and disperse collision energy, minimizing passenger compartment deformation.
The use of third-generation ultra-high strength steel significantly improves formability compared with first-generation steel. Key structural enhancements include reinforced front-end components, a multi-piece hot-stamped lower side area, an improved frontal crash load path, and a multi-load path structure for side impacts.
ADAS features include Forward Collision-Avoidance Assist (FCA) 1.5/2.0, Lane Keeping Assist (LKA), Blind-Spot Collision-Avoidance Assist (BCA), Safe Exit Warning (SEW), Safe Exit Assist (SEA), Intelligent Speed Limit Assist (ISLA), Driver Attention Warning (DAW), Blind-Spot Viewer Monitor (BVM), High Beam Assist (HBA), Smart Cruise Control (SCC), Emergency Stop, Navigation-based Smart Cruise Control (NSCC), Lane Following Assist 2 (LFA), Highway Driving Assist (HDA), Rear View Monitor (RVM), Surround View Monitor (SVM), Rear Cross-Traffic Collision-Avoidance Assist (RCCA), Forward/Side/Reverse Parking Distance Warning (PDW), Forward/Side/Reverse Parking Collision-Avoidance Assist (PCA) and Remote Smart Parking Assist 2 (RSPA).
The new NEXO is coming to global markets later this year.
435 miles range in 5 min for a BEV? Don't think so. At 250 watt hours per mile which is typical for 5 passenger sedan in temperate climate not hot or cold. That's 109 kilowatt hours worth of charge forgetting the 10,% charge loss plug to.pack. That's 109x3.6 million joules or 392 mega joules delivered over a 5 minute span or 300 seconds all at peak rate. That is 1.3 million joules per second thats 1.3 megawatts of current. No way no how is 110 kWh pack taking a 12C charge and also no charge standard on earth got LDV is above 1 MW even the semi truck sized liquid cooled megacharger is only max 3 MW and it takes huge liquid cooled cables and sockets.
They have to mean their FCV can take hydrogen gas at a rate that fills it's 6.3Kg tank in under 5 min. Then you have to look at each Kg of H2 takes 55.2 kWh to produce via electrolysis, the ten percent more to compress it to 300 bar, yeah it's crazy stupid to turn water into H2 then only get 50% of all that back as electrons. Hydrogen is a problem looking for a solution.
Posted by: JamesDo88039200 | 07 April 2025 at 03:07 PM
Agree, James. to use H2 for daily commuting is a waste of energy. PHEVs would represent more efficient use of Renewable Energy when charged directly with RE whenever available. Those living in apartments and condos can charge their PHEVs at work with solar car covers having PV panels on top of their at-work parking lot..
However, to be a truly ZEV (Zero-Emission Vehicle), PHEVs should use H2 to for when rapid fill-up is needed, and also during periods of very high power demand on the power grid, PHEVs can run on fuel to spare excessive power demand on the grid.
The consumption of green H2 made from grid-surplus Renewable Energy will encourage the growth of RE because RE investors can still get revenue from grid-surplus RE electricity.
So, all FCV makers should make them as Plug-in FCVs. instead of 100% H2-dependent FCVs.
Plugged-in FCVs only require ONE H2 filling station per metroplex, because they don't need H2 refilling that often, only less than once per month or just before a long trip, thus would greatly simplify the H2 infrastructure.
Posted by: Roger Pham | 07 April 2025 at 07:09 PM
This is the correct way to go.
https://www.science.org/doi/10.1126/sciadv.aao7233
Posted by: yoatmon | 08 April 2025 at 07:43 AM
Hi Yoatmon,
"Ultrafast all-climate aluminum-graphene battery with quarter-million cycle life" is PERFECT for PHEVs. It can be juiced up real fast when parked and charged during stops for food or business, so can run all day without requiring the use of range extender. With such high durability, it will last for the life of the car even if used for 95% of all mileage of the car.
Only needing the range extender for 5% of the time for the occasional long trips, NOT for local driving, while the engine range extender can reduce the battery capacity in a PHEV to 1/5 of that of a BEV.
Posted by: Roger Pham | 08 April 2025 at 12:11 PM
@ Roger Pham:
Presently, only one of the three valence electrons of Aluminum is being employed. Research is convinced that in short time all three will be employed resulting in a considerable increase of energy density and subsequently rendering the use of range extenders to absurdity.
Posted by: yoatmon | 09 April 2025 at 04:06 AM