Australian electrolyser manufacturer Hysata has launched an AI-optimised manufacturing platform and commissioned its first production line at its 8,500-square-metre headquarters in Port Kembla, NSW.
According to Hysata, its HysataFab platform integrates artificial intelligence, real-time monitoring, robotics and inline quality testing to produce up to 15 per cent more product from the same physical production line.
The launch coincides with a $49 million grant from the Australian Government through the Australian Renewable Energy Agency (ARENA) under the Future Made in Australia Innovation Fund. The grant will support the establishment and scale-up of Hysata’s electrolyser manufacturing capability, with Hysata matching the funding from private capital.
Hysata said the first HysataFab project represents an investment of close to $100 million and includes three production lines covering electrode, membrane, and cell and stack manufacturing.
The facility will initially have capacity of 50MW per year on a single-shift basis, with the electrode line now operational and the remaining lines to follow.
Continuous operations could increase the facility’s capacity to 200MW per year, which Hysata said would make it the largest electrolyser manufacturing facility in the southern hemisphere. The company described HysataFab as a repeatable manufacturing template that could be deployed elsewhere as demand increases.
Hysata Chief Executive Officer Paul Barrett said the platform was intended to improve manufacturing efficiency alongside the company’s electrolyser technology.
“Hysata was built around a simple idea, which is to do more with less. Our electrolyser gets more hydrogen from every megawatt of electricity. HysataFab now gets more product from every manufacturing line.”
The company’s electrode production line uses AI to analyse thousands of data points from each electrode produced. Hysata said it has built a digital record containing more than 57 billion process data points over three years and generates more than 100 million additional data points each day.
Hysata Principal AI Engineer Shaun Maris said the system uses this information to monitor production and identify potential issues during manufacturing.
“Every electrode has a digital fingerprint. We capture thousands of data points as it moves down the line, and the AI reads that in real time,” Maris said.
“It picks up drift before it turns into a defect, and closes the loop back into process control.”
The Australian Government grant was announced at the Port Kembla site by Minister for Climate Change and Energy Chris Bowen and Minister for Industry and Innovation and Science Tim Ayres.
Bowen said the project would support manufacturing and employment in the Illawarra while contributing to domestic clean-energy technology production.
“Making electrolysers here in Australia is a huge opportunity to strengthen our manufacturing capability, back local innovation, create skilled jobs and seize a bigger share of the global clean-energy technology market,” Bowen said.
ARENA CEO Darren Miller said the funding was focused on moving the technology from development into commercial-scale manufacturing.
“Turning breakthrough technology into commercial-scale manufacturing is one of the hardest steps in innovation, and it is where ARENA can make the most difference,” Miller said.
Hysata said its capillary-fed electrolyser operates at 95 per cent efficiency, equivalent to 41.5kWh per kilogram of hydrogen, which it says provides around 20 per cent more hydrogen per megawatt than incumbent electrolyser technologies.
The company has raised more than $220 million from global investors and said its first binding megawatt-scale export order was signed in June 2026 with a global heavy-industry customer, with delivery scheduled for the first half of 2027. Electrodes for the system will be manufactured at HysataFab.
Hysata also said it has completed a field trial with ACWA Power in Saudi Arabia, holds joint development agreements with POSCO and Vestas, and is working with tier-one customers across a multi-gigawatt pipeline in hard-to-abate sectors.
