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Thatcham Research ‘insurability’ consultancy supports Toyota and industry consortium partners in pioneering powertrain conversion

Press release -

Thatcham Research ‘insurability’ consultancy supports Toyota and industry consortium partners in pioneering powertrain conversion

Thatcham Research, renowned for research-led automotive risk intelligence, is hailing Toyota’s prototype hydrogen fuel cell variant of its iconic Hilux pick up as a benchmark in sustainable vehicle design strategy.

The Toyota Motor Manufacturing (UK) Ltd (TMUK) led project is a collaborative effort to pioneer zero-emission technology in the commercial vehicle market, reflecting evolving customer demand, technology developments and Toyota's 360-degree approach to sustainable mobility, funded by the UK Government's Advanced Propulsion Centre.

This endeavour assembles a consortium of strategic partners, led by Ricardo and including ETL (European Thermodynamics) and D2H Group, to adapt Toyota Mirai fuel cell components, thus transforming the Hilux pick-up to hydrogen fuel cell power.

Throughout the design and prototype build phases, Thatcham Research has provided valuable insights focused on safe and sustainable repair. Thatcham Research is also building a training suite to drive dedicated hydrogen skills and awareness of safe handling practices into the repair ecosystem, as it has done with its ‘EV Ready’ electric vehicle training programmes.

Mark Fry, Thatcham Research's Engineering Manager, said: "By bringing together a consortium of skilled partners to not only transform the Hilux but also consider future customers and wider market requirements, this project makes for an excellent case study in sustainable vehicle design. Toyota’s comprehensive approach goes beyond the technical intricacies of the conversion to consider factors such as Total Cost of Ownership, insurance risk rating and repairability, all of which are vital to creating a positive ownership experience for any new vehicle.”

The ground-breaking pick-up was revealed at Toyota Manufacturing UK’s Burnaston car plant in Derbyshire, with the brand describing its debut as: “further demonstration of the broad scope of Toyota’s multi-technology strategy for ultimately achieving carbon-free mobility.”

Fry added: “It is important that the commercial vehicle market is catered for in the drive for zero emission vehicles. The fuel cell Hilux provides an alternative solution to Battery Electric Vehicles, offering diversity in vehicles and powertrains. Thatcham Research is proud to support the repair industry in becoming Hydrogen FCEV Ready, as well as EV Ready.”

This collaborative model stands as a testament to Thatcham Research's unwavering commitment to excellence and innovation in safety, security, and sustainable repair.



Thatcham Research is the independent voice of automotive safety, security & repair, advising motorists, insurers and vehicle manufacturers to help reduce accident frequency, severity and costs and to realise the vision of ‘Safer cars, fewer crashes’, while driving standards in vehicle security.

As well as its world leading crash and track research, Thatcham Research develops repair methods amongst a number of other products and services within the collision repair industry for insurers, motor manufacturers, equipment manufacturers and suppliers.

In addition, Thatcham Research has administered the Association of British Insurer’s (ABI) Group Rating system for the past 50 years. Group Rating is an advisory system intended to provide insurers with the relative risk of private cars and light commercial vehicles.

A founder member of the international Research Council for Automobile Repairs (RCAR), Thatcham Research has also been a member of the European New Car Assessment Programme (Euro NCAP) since 2004.


Tom Flisher

Tom Flisher

Press contact PR Manager 07876 755 615
Stewart Mitchell

Stewart Mitchell

Press contact PR Executive PR and communication
Max Norstrom

Max Norstrom

Press contact PR Executive

Thatcham Research: Automotive Risk Intelligence

Thatcham Research is the automotive risk intelligence company dedicated to understanding the opportunities and risks of new vehicle technology and supporting our partners in identifying the best strategies for its safe, secure, and sustainable adoption.

The independent voice of automotive safety, security, and repair, we work in close partnership with insurers, vehicle manufacturers, technology providers and government, providing rigorous engineering-grade research and data to help minimise uncertainty presented by changes in technology and regulation.

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