The urgent global demand for sustainable transportation has accelerated the development of green hydrogen-powered electric vehicles (GHEVs). This paper presents a modular prototype architecture integrating proton exchange membrane (PEM) fuel cells, a high-efficiency DC–DC boost converter, and hybrid supercapacitor energy storage. The work encompasses the entire hydrogen value chain, including production, distribution, and on-board power management. Emphasis is placed on realistic dynamic load matching, power regulation, and scalability with consideration for operational environment factors. Experimental validation demonstrates that the prototype achieves a power density of 0.32 W/cm² at 80 °C and 3 atm, with an efficiency of approximately 55%, confirming scalability trends comparable to larger commercial PEM stacks. This research provides strategic insights for designing adaptable hydrogen mobility solutions aligned with India’s green energy initiatives.
Electric Vehicles (EVs), Green Hydrogen Electric Vehicles (GHEVs), PEM Fuel Cells, DC–DC Boost Converter, Hybrid Energy Storage, Fuel Cell Electric Vehicles (FCEVs), Energy Management