How a Horizon Fuel Cell Helped a High School Team Win the Shell Eco-Marathon
Jefferson County Public Schools’ Journey with Hydrogen-Powered Vehicles
In the world of fuel cell technology, high school students aren’t typically the first group that comes to mind when you think of competition-winning hydrogen-powered vehicles.
However, Charles Sprague, an engineering teacher at Jefferson County Public Schools in Colorado, has spent the last 11 years proving that high school students can compete—and win—on the same level as university teams.
His students, with the help of Horizon Educational’s hydrogen fuel cell stacks, have taken home multiple first-place and runner-up titles at the Shell Eco-Marathon, an international competition where teams design and build ultra-efficient vehicles. But their biggest triumph came in 2015, when a last-minute fuel cell swap—coordinated across two continents—helped them secure first place in Detroit.
A Decade of Hydrogen Innovation in the Classroom
Since 2014, Sprague’s high school engineering students have been working with hydrogen fuel cells. They’ve integrated them into high-efficiency vehicles designed for competition, specifically in the Prototype and Urban Concept divisions of the Shell Eco-Marathon. Over the years, the team has experimented with both the Horizon 1000W XP and the H-2000 fuel cell stacks to push the limits of hydrogen vehicle technology.
The goal? To show students how clean energy technology can be applied to real-world engineering challenges.
“It shows them how technology is out there and how it can be used. It also teaches them how to work in teams on large-scale engineering projects with real-world applications.” – Charles Sprague
In addition to learning about fuel cell integration, aerodynamics, and vehicle design, students also develop essential presentation and communication skills, explaining fuel cell technology to industry experts, sponsors, and judges at competitions.
A Fuel Cell, A Flight, and A First-Place Finish
The team’s most dramatic success story happened in 2015, when a major setback threatened their participation in the Shell Eco-Marathon Americas in Detroit.
The team had borrowed a used fuel cell from the University of Colorado Denver, but just days before the competition, they realized it wasn’t going to provide enough power for their vehicle.
With their car already in transit to Detroit, Sprague made a last-minute call to Horizon Educational to see if they could secure a replacement fuel cell in time.
“This was 12 to 14 hours before I was supposed to get on a plane. There were no fuel cells available in the U.S.—the only one in stock was in Prague, Czech Republic.”
Horizon Educational immediately shipped the fuel cell from Prague, but it encountered multiple delays, including customs issues and tornado-related flight disruptions. Despite the challenges, the fuel cell arrived at the team’s hotel on the morning of race day.
“We saw it come in the door during breakfast, grabbed it, and my electrical team spent half a day installing it. We got it through tech inspection just in time—and the next day, we raced.”
Against all odds, the team won first place in the hydrogen fuel cell division of the 2015 Shell Eco-Marathon Americas, beating out university-level teams.
Why Horizon Fuel Cells?
Sprague and his team have continued using Horizon Educational’s fuel cell stacks ever since. When asked why they chose Horizon over competitors like Ballard, he highlighted several key reasons:
- Ease of Use: The XP1000 fuel cell stack is plug-and-play, making it simple for students to integrate into their vehicle designs.
- Strong Customer Support: Horizon has consistently provided fast and reliable assistance, including shipping vital documentation for safety inspections at Shell competitions.
- Durability & Performance: The fuel cells are highly efficient, and with proper moisture management, they maintain optimal power output for racing.
“We’ve only ever used Horizon fuel cells. They’ve been reliable, and we’ve always received great customer support.”
Fuel Cell Innovation: Lessons from the Lab to the Track
The team has learned critical lessons about fuel cell maintenance and optimization over the years. One of their biggest discoveries involved moisture levels in the hydrogen membranes.
“Colorado is really dry, with humidity levels around 8-12%. In humid environments like Indianapolis, the fuel cells work better because they naturally absorb moisture.”
To solve this, the team experimented with artificial rehydration, using a household humidifier to keep the fuel cell membranes hydrated.
“We let the fuel cell run with a humidifier behind it for eight hours, and we improved voltage by about 12 volts.”
This simple yet effective solution has helped extend the lifespan of their fuel cells and ensure consistent performance year after year.
What’s Next? The Future of Hydrogen Education
As Sprague prepares to retire after 11 years of coaching high school engineers, he’s looking for ways to continue inspiring young students through hydrogen technology. One of his most successful STEM outreach programs involved elementary school students using Horizon’s DIY fuel cell kits to design their own hydrogen-powered cars—using only household materials.
“I gave them the fuel cell and said, ‘You figure out how to make the car.’ The students loved it—it was the most engaging project they’d ever done.”
This initiative was gaining traction across four major school districts before the pandemic put it on hold. Now, with new hydrogen STEM kits like Horizon’s Sprint and H2GP programs, there’s an opportunity to revive and expand this hands-on hydrogen education for younger students.
A Legacy of Clean Energy Education
Charles Sprague and his students have left an undeniable impact on hydrogen fuel cell education and competition. Their groundbreaking work, coupled with Horizon Educational’s support, has demonstrated that high school students can compete at the highest levels of clean energy innovation.
With their long list of first-place finishes, runner-up titles, and even a documentary feature from Shell, this high school team has set the standard for hydrogen fuel cell education in the U.S.
“It’s not just about winning races. It’s about preparing students for the future—showing them that hydrogen fuel cells are a real, viable technology that they can work with in their careers.”
And with a new generation of students stepping up to the challenge, the future of hydrogen education looks brighter than ever.
Want to Learn More?
- Check out Horizon Educational’s Fuel Cell Stacks
Interested in bringing hydrogen education to your classroom?