Australian electrolyser manufacturer Hysata has launched HysataFab, an artificial intelligence (AI)-optimised manufacturing platform, and commissioned its first production line at the company’s 8,500-square-metre headquarters in Port Kembla, New South Wales.
The company said HysataFab integrates real-time monitoring, robotics and inline quality testing to improve manufacturing efficiency. The platform is designed to produce up to 15% more product from the same physical production line.
The launch coincides with the Australian Government announcing a A$49 million grant for Hysata through the Australian Renewable Energy Agency (ARENA) under the Future Made in Australia Innovation Fund.
A$100 Million Manufacturing Project
HysataFab is designed as a repeatable manufacturing platform rather than a single factory. Its first deployment at Port Kembla represents a project worth close to A$100 million and includes three production lines covering electrode, membrane, and cell and stack manufacturing.
The facility has an initial manufacturing capacity of 50 MW per year on a single-shift basis. The electrode production line has commenced operations, while the membrane and cell and stack production lines are expected to follow.
Hysata said continuous operations could increase the facility’s production capacity to 200 MW per year, which would make it the largest electrolyser manufacturing facility in the Southern Hemisphere.
The company plans to replicate the HysataFab platform at additional sites as demand grows, with the potential to scale manufacturing toward gigawatt-level capacity.
Government Grant Supports Manufacturing Scale-Up
Hysata has raised more than A$220 million from global investors to date. The A$49 million ARENA grant covers approximately half of the Port Kembla project cost, with the remainder being funded by Hysata through private capital.
The government funding will support the establishment and scale-up of Hysata’s electrolyser manufacturing capability, while the company has developed and funded the HysataFab AI manufacturing platform separately.
Chris Bowen, Australia’s Minister for Climate Change and Energy, said the project would support manufacturing, skilled employment and clean-energy technology development in the Illawarra region.
ARENA Chief Executive Officer Darren Miller said the funding is intended to support the transition of Hysata’s electrolyser technology from an Australian innovation into commercial-scale domestic manufacturing.
AI Platform Uses Billions of Manufacturing Data Points
Hysata said its electrode production line is the world’s first electrolyser manufacturing line to use AI to analyse thousands of data points from every electrode produced.
The company has accumulated more than 57 billion process data points over three years through research, testing and manufacturing activities. It currently generates more than 100 million additional data points each day.
The system creates a digital record for each electrode and uses real-time data to identify process variations and potential defects. AI agents analyse manufacturing data and feed the findings back into process controls to improve production quality and yield.
Hysata said the AI system conducts close to 10,000 analytical queries each day, allowing production processes to be continuously adjusted based on manufacturing data.
Hysata Electrolyser Reports 95% Efficiency
Hysata’s capillary-fed electrolyser operates at a reported 95% efficiency, consuming approximately 41.5 kWh per kilogram of hydrogen.
According to the company, the technology can produce around 20% more hydrogen per megawatt than incumbent electrolyser technologies.
Hysata said its electrolyser design also requires fewer components and has lower capital costs per megawatt of manufacturing capacity, while HysataFab is intended to improve the efficiency and output of the manufacturing process itself.
First Export Order Signed
The manufacturing launch follows Hysata’s signing of its first binding megawatt-scale export order with a global heavy-industry company in June 2026. The electrolyser systems are scheduled for delivery during the first half of 2027, with electrodes for the project to be manufactured at HysataFab.
Hysata has also completed a field trial with ACWA Power in Saudi Arabia and has joint development agreements with POSCO and Vestas.
The company said it is working with tier-one customers across a multi-gigawatt pipeline, particularly in hard-to-abate sectors.
Focus on Industrial Hydrogen Applications
Hysata CEO Paul Barrett said the company’s focus is on industrial applications where hydrogen is required as a molecule rather than as an alternative to direct electrification.
The company is targeting sectors including steel, fertiliser and refining, as well as emerging markets for green steel and sustainable fuels for aviation and shipping.
Hysata said the cost of green hydrogen remains closely linked to electrolyser efficiency and renewable electricity costs, making improvements in hydrogen production efficiency important for the commercial expansion of the sector.
Global Electrolyser Market Continues to Expand
The launch comes amid continued growth in global electrolyser deployment. According to the International Energy Agency, installed electrolysis capacity doubled in 2025 to more than 4 GW, with an additional 2.5 GW under construction for 2026.
The Hydrogen Council estimates that committed investment in clean hydrogen has reached approximately US$130 billion across more than 570 projects, representing an 18% increase over the previous year. Around 90% of this capacity is either under construction or already operational.
Hysata’s Port Kembla facility is intended to position the company to supply electrolyser systems as global demand for clean hydrogen technologies expands.
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