Rheinmetall Advances Green Hydrogen Production with New Electrolysis Electrode Technology

(IN BRIEF) Rheinmetall has completed development of a new noble-metal-free electrode technology for alkaline electrolysis, enabling more efficient and cost-effective production of green hydrogen at industrial scale. Led by KS Gleitlager GmbH under the German government-funded E²ngel project, the technology delivers higher power density and efficiency while avoiding precious metals. Pilot production is set to begin next year, supporting multi-megawatt electrolyser systems and scalable hydrogen infrastructure across Europe.

(PRESS RELEASE) DÜSSELDORF, 7-Jan-2026 — /EuropaWire/ — Rheinmetall has completed the development of a new electrode technology designed to significantly improve the efficiency and scalability of alkaline water electrolysis, marking an important step toward cost-effective, industrial-scale production of green hydrogen. Preparations are already underway for pilot manufacturing, with series-oriented production processes now defined.

The development was led by KS Gleitlager GmbH, which acted as consortium coordinator for a three-year research initiative supported by the German government. The project, titled Noble Metal-free Electrodes for the Next Generation of Alkaline Electrolysis (E²ngel), forms part of Germany’s national hydrogen strategy and focuses on replacing precious-metal catalysts with highly scalable alternatives.

The newly developed electrodes are designed to increase electrolyser performance while reducing system costs. By eliminating the need for noble metals, the technology enables a substantial improvement in power density and efficiency compared with existing alkaline electrolysis solutions. According to Rheinmetall, the approach can either double power density or deliver efficiency gains of more than ten percent, lowering overall investment requirements for hydrogen production facilities.

Dr. Karsten Lange, head of the E²ngel project, said the new electrode design allows electrolysis systems to operate more efficiently and at higher output levels than current technologies. This performance improvement directly supports more economical green hydrogen production by reducing both capital expenditure and system complexity.

Rheinmetall’s in-house capabilities in special alloy development, metallic coating techniques, and advanced forming and joining processes enabled rapid progression from catalyst development to industrially viable production methods. Validation and qualification activities were carried out in collaboration with German Aerospace Centre and McPhy Energy Germany. The DLR Institute of Technical Thermodynamics tested multiple electrode variants, while McPhy evaluated system performance during the final project phase.

Testing results exceeded the project’s original targets for cell voltage and current density, confirming that the precious-metal-free electrodes outperform more complex and cost-intensive conventional designs. The findings demonstrate the technology’s suitability for large-scale deployment and its potential to support rapid expansion of green hydrogen infrastructure.

Pilot production is scheduled to begin next year at Rheinmetall’s St. Leon-Rot site. The production line is designed to accommodate electrode formats of up to two metres, enabling use in multi-megawatt electrolyser systems. Volume scalability was incorporated into the manufacturing concept from the outset, ensuring readiness for future demand as hydrogen markets expand.

Dr. Klaus Pucher, CEO of the responsible Rheinmetall business unit, said the project contributes meaningfully to an affordable and resilient energy transition. He noted that the technology supports reduced reliance on imported fossil fuels while strengthening the long-term security of Germany’s and Europe’s energy supply.

Media Contacts:

Oliver Hoffmann
Head of Public Relations
Rheinmetall AG
Tel.: +49-(0)211 473 4748

SOURCE: RHEINMETALL AG