Southwest Research Institute (SwRI) has developed a groundbreaking controller system for hydrogen-powered vehicles, enabling comprehensive testing of fuel cell stacks in controlled environments without the need for vehicle operation. This innovative approach allows engineers to evaluate fuel cell reactions under various driving conditions, leading to the creation of algorithms to enhance vehicle performance and efficiency. By precisely managing operations such as fuel flow rates, air flow rates, and temperatures, SwRI's system eliminates the necessity of road testing for benchmarking. The project, internally funded by SwRI, began with a detailed analysis of a hydrogen fuel cell-powered consumer vehicle, followed by the extraction and testing of the fuel stack. The team has successfully developed new testing methods and is now focusing on predictive control models to optimize fuel cell humidity management. Proper humidity levels play a crucial role in enhancing fuel cell performance and preventing issues like flooding or high internal resistance. As the project progresses, SwRI aims to collaborate with commercial clients to expand testing to more complex, multi-stack setups designed for heavy-duty vehicles. This initiative aligns with SwRI's investment in cutting-edge technologies, including a significant investment in 2024 to advance its knowledge base and reinforce its position as a leader in the science and technology sector. By pioneering new control models and testing methodologies, SwRI is driving innovation in the future of fuel cells, particularly in heavy-duty applications, to achieve commercial viability and operational efficiency.