Toyota is going all-in on sustainability with next-generation electric and hydrogen technologies

Toyota recently hosted its Technical Workshop, an event that allowed the media to explore and experience the latest technologies driven by the company's focus on electrification, intelligence, and diversification. The workshop showcased Toyota's next-generation electrification technologies, featuring the BEV Factory and the Hydrogen Factory, led by President Takero Kato and soon-to-be President Mitsumasa Yamagata, respectively. Both leaders provided insights into the upcoming products and business outlook of these units, unveiling over 20 next-generation items.

Executive Vice President Hiroki Nakajima, who conceptualized the workshop, emphasized the theme of "Let's Change the Future of Cars" and shared his vision as Chief Technology Officer. He highlighted Toyota's history of overcoming challenges and its commitment to leveraging technology to transport customers into the future and connect cars to society.

The workshop presented various innovations in battery electric vehicles (BEVs) and hydrogen technology. President Kato, speaking for the first time since the launch of the BEV Factory, expressed the unit's goal of transforming cars, manufacturing processes, and work culture to contribute to Toyota's future success. He announced that the next-generation BEVs would be available in the market by 2026, with Toyota aiming to sell 1.7 million of the projected 3.5 million BEVs by 2030 as next-generation models.

Toyota also unveiled two next-generation lithium-ion batteries for its BEVs: a performance version and a popularization version. The performance version aimed to double the cruising range of conventional batteries to 1,000 km, improve vehicle efficiency, reduce costs by 20 percent, and offer rapid charging times of 20 minutes or less. On the other hand, the popularization version focused on reducing costs by 40 percent and increasing the cruising range by 20 percent compared to current batteries. Toyota aimed to combine the best aspects of both batteries to create a high-performance version that would further enhance the cruising range by 10 percent and reduce costs by 10 percent.

In addition to battery advancements, Toyota highlighted its work on all-solid-state batteries, which were expected to revolutionize BEVs by offering increased power output, longer range, and shorter charging times. The challenge with all-solid-state batteries was the potential for shorter battery life due to the expansion and contraction of solid electrolytes during charging and discharging. Toyota announced a newly discovered technology to overcome this challenge and revealed revised plans for commercializing all-solid-state batteries from 2027 to 2028.

The workshop also showcased Toyota's focus on vehicle design and aerodynamic technology to improve BEV performance. Toyota collaborated with the Space Systems Division of Mitsubishi Heavy Industries to apply hypersonic rocketry technology to cars, aiming to reduce drag coefficient (Cd) to a tenth of that for existing car bodies (0.20). This technology allowed for stylish and aerodynamic designs, regardless of the car's shape or material. Toyota aimed to commercialize this technology within three years.

President Kato emphasized that the advancements in BEVs would be supported by improvements in manufacturing processes. Toyota planned to implement modular structures and self-driving assembly lines to reduce production processes, plant investment, and production preparation lead times. The new modular structure would divide car bodies into three sections, with only the center section housing the batteries. Toyota's giga-casting technology aimed to reduce costs and weight while improving productivity. The self-driving assembly line concept eliminated conveyors, allowing for more flexible factory layouts and shorter lead times for mass production.

The workshop also focused on Toyota's efforts in hydrogen technology. President Yamagata of the Hydrogen Factory highlighted the importance of a coordinated approach to commercialization, including development, production, and sales. Toyota aimed to offer affordable products by pursuing sufficient volume, and they had received offers for 100,000 fuel cell vehicles by 2030. Toyota showcased a next-generation fuel cell system for commercial vehicles that improved driving performance and fuel economy while reducing manufacturing costs for onboard tanks. The company also explored technologies for producing hydrogen, including water electrolysis and utilizing biogas.

Toyota's advancements in hydrogen technology included next-generation fuel cell systems with improved generating capacity, durability, and cost-effectiveness. The next-generation fuel cell systems increased generating capacity by 30 percent and extended the vehicle's maintenance-free lifespan. These systems also halved the cost of fabricating a stack and increased the range by 20 percent, enabling long-distance travel without refueling. Toyota's expertise in real-time measurement, nanoscale mapping of chemical reactions, and precision coating of catalysts contributed to the development of these highly competitive next-generation fuel cell systems, scheduled for release in 2026.

To further enhance the adoption of hydrogen, Toyota explored advancements in hydrogen production and storage. The company developed a water electrolyzer utilizing fuel cell technology from the Mirai, sharing 90 percent of its parts with hydrogen production equipment. Toyota also showcased efforts to develop standardized hydrogen tanks and alternative tank shapes, offering cost reductions, space optimization, and design flexibility. Additionally, Toyota aimed to develop half-size cells for its next-generation fuel cell systems, expanding their potential applications across various vehicle sizes and models.

Through the Technical Workshop, Toyota aimed to share its technological advancements with the media and stakeholders. The event also provided an opportunity for the company's engineers to gain insights into customer needs, fostering further research and development. Toyota's commitment to "changing the future of cars" was exemplified by its focus on electrification, intelligence, and diversification, as well as its dedication to improving manufacturing processes and pushing the boundaries of technology in the pursuit of ever-better cars.