High-pressure hydrogen tanks in early fuel-cell vehicles like the Toyota Mirai and Hyundai ix35 are nearing the end of their 15-20 year certified lifespan. Upon expiry, these carbon-fibre tanks must be replaced for vehicle operating licenses to remain valid. Germany currently lacks a certified procedure for extending tank approval. Replacement can cost a five-figure sum, often exceeding the low used-car market value of these older models, some under €10,000. This issue affects approximately 1,500 fuel-cell vehicles in Germany, predominantly commercial. While the global fuel-cell passenger car market remains small, some manufacturers continue investing in the technology.
According to the publication Vision Mobility, the first hydrogen-powered passenger cars will soon reach the end of the certification period for their high-pressure hydrogen tanks. Depending on their design, the carbon-fibre-reinforced plastic (CFRP) tanks are certified for an operational lifespan of 15 to a maximum of 20 years. Once this period expires, the tanks must currently be replaced, as the vehicle’s operating licence is no longer valid.
The issue affects some of the earliest fuel-cell vehicles on the market, including the first-generation Toyota Mirai, the Hyundai ix35 Fuel Cell and the Honda FCX Clarity.
According to Germany’s Federal Motor Transport Authority (Kraftfahrt-Bundesamt), around 1,500 fuel-cell vehicles are currently registered in the country. Vision Mobility reports that most of these vehicles are operated by companies, public authorities or research institutions, while private ownership remains uncommon.
Depending on the model, replacing expired hydrogen tanks can reportedly cost a five-figure sum. At the same time, older fuel-cell vehicles often command relatively low prices on the used car market. According to Vision Mobility, early examples of the Toyota Mirai are now sometimes available for less than €10,000. In such cases, the cost of replacing the hydrogen tanks could exceed the vehicle’s remaining market value.
According to Vision Mobility, Germany currently has no certified procedure for extending the approval of hydrogen tanks once their certified service life expires. While the tanks are subject to visual inspections as part of the vehicle’s regular roadworthiness testing, there is no established process for a technical reassessment followed by a renewal of the approval period.
Despite the issue, the economic relevance of the fuel-cell passenger car segment remains limited. According to data from SNE Research, 16,011 fuel-cell vehicles were newly registered worldwide in 2025. While this represented an increase of 24.4 per cent compared to the previous year, overall volumes remained very low. In Europe, new registrations fell by 23.1 per cent to just 566 vehicles.
Some manufacturers nevertheless continue to invest in the technology. BMW plans to introduce a fuel-cell version of the X5 from 2028, while the Hyundai Nexo remains one of the few fuel-cell passenger cars currently available as a new vehicle in Europe.
vision-mobility.de (in German)
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