Performance and cost of automotive fuel cell systems with ultra-low platinum loadings

► An automotive polymer-electrolyte fuel cell system with low Pt loading has been analyzed. ► Design-point efficiency affects part load performance and manufacturing cost. ► Lowering the efficiency from 50% to 40% decreases the system cost by 25%. ► The penalties are 2-4% decrease in drive-cycle efficiency and 6% decrease in fuel economy. ► The advantages of further lowering the efficiency from 40% to 35% are marginal.