Fontaine Modification is leading a consortium to develop a Class 6 fuel cell truck for “middle mile” delivery logistics. The team includes Ballard Power Systems, Forsee Power, and Linamar Corporation.

Fontaine Modification integrates the vehicle and systems. It will build the FCEV on a 26,000-pound GVWR straight truck chassis at its Charlotte, N.C., modification center. Ballard Power Systems supplies the fuel cell system. Forsee Power provides the high-voltage battery system. Linamar contributes the eAxle.

“Fontaine Modification is excited to lead this team of well-established companies that are committed to bringing clean mobility solutions to the commercial vehicle market,” said David Brosky, Fontaine Modification director, sales & business development – eMobility. “We are on track to complete a pilot unit this summer. The team will conduct independent track testing on the pilot unit before delivering it to its first customer.”

Class 6 Fuel Cell Truck Targets Middle-Mile Use Cases

Fontaine’s sister company, Kentucky Trailer, will build a lift-gated dry freight body for the pilot vehicle. If the field trial succeeds, Fontaine could start full production of the Class 6 fuel cell truck as early as late 2026.

“The middle-mile segment covers freight hauled between warehouses or distribution centers,” Brosky explained. “This segment is usually the longest, with runs within states or across regions of typically 300 to 500 miles. It’s that need for longer range that makes a fuel-cell system the best zero-emission option for efficiently powering a middle-mile truck.”

The project gives each partner a chance to showcase new technologies and support fleet sustainability goals.

“Ballard is showcasing the value of its latest fuel cell system FCmove-XD in North America for the first time,” said Nicolas Pocard, Ballard Power Systems vice president marketing & strategic partnerships. “The module provides an easy integration platform for vehicle OEMs and integrators. It is designed to deliver up to 60% fuel efficiency with volumetric power density of 0.36kW/L. And last over 30,000 hours in operation. Developed for volume production, this commercial and scalable fuel cell module provides a competitive total cost of ownership.”

Battery-Fuel Cell Integration Enhances Range and Efficiency

The team designed the truck to balance fuel cell and battery power for peak performance, range, and durability.

“Battery systems are critical to fuel-cell-electric vehicles. Depending on the situation, the FCEV is driven by the battery, by the fuel cell, or by both if extra power is needed,” said Jeremy Hiler, Forsee Power sales manager, truck and off highway. “It was critical to offer a solution that can meet the technical needs of long distance (power peaks on highway) and local deliveries, optimizing the cost.”

Fleet Operators Gain Efficiency, Comfort, and Savings

The pilot vehicle delivers benefits beyond zero emissions, helping fleets cut costs and improve driver experience.

“The vehicle’s low-maintenance design helps fleet operators reduce operational costs, while its quiet propulsion system provides a smoother and less intrusive experience for drivers and others on the road,” said Kevin Ledford, vice president of engineered product at Linamar. “Regenerative braking recoups energy that the vehicle would otherwise lose and boosts overall efficiency. Separately, it reduces wear and tear on critical components, leading to lower maintenance costs and improved durability.”