Robots Power France’s Hydrogen Ambitions

Helion’s Aix-en-Provence plant uses robotics and AI to ramp zero-emission fuel cell output, setting a new benchmark for Europe’s hydrogen sector.

20 Jun 2025

Helion Hydrogen Power, a subsidiary of rail group Alstom, inaugurated its Delta facility in June in Aix-en-Provence, southern France. Boasting integrated robotics, smart sensors and adaptive software, Delta is now among Europe’s largest automated fuel cell stack factories. The plant aims to accelerate supply of zero-emission modules for transport, industry and backup power.

Until recently, fuel cell assembly was labour-intensive. Delta’s automation-first design automates tasks such as membrane electrode assembly and stack stacking, reducing manual handling. “We’re not just assembling fuel cells,” noted a Helion engineer. “We’re reinventing manufacturing for a clean energy era.” Its digital core allows rapid reconfiguration of designs and production volumes to match evolving demand.

High-end automation entails sizeable capital outlays and ongoing software updates. Reliance on proprietary systems may constrain future flexibility, while maintenance of complex robotics can add operational costs. Proponents argue that the benefits of lower error rates, consistent quality and scalable throughput more than offset these challenges over the plant’s life cycle.

Helion’s move reflects a broader trend among fuel cell producers. Ballard Power and US-based Nuvera have announced plans to integrate advanced data analytics and automation at their manufacturing sites. These developments coincide with the European Union’s strategy to deploy up to 10 million tonnes of renewable hydrogen annually by 2030, a key element of its net-zero roadmap.

As hydrogen demand grows under climate mandates and industrial decarbonisation, Delta’s technology may become a sector benchmark. Yet questions remain over the pace of adoption, standardisation of processes and alignment with EU certification schemes. For French industry and policymakers, the challenge will be to ensure that automation supports both scale-up and supply chain resilience.