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Cost is one of the critical factors in the commercialization of PEM fuel cells in automotive markets. Arthur D. Little has been working with the U.S. Department of Energy, Office of Transportation Technologies to assess the cost of fuel-flexible reformer proton exchange membrane (PEM) fuel cell systems based on near-term technology but cost modeled at high production volumes and to assess future technology scenarios. Integral to this effort has been the development of a system configuration (in conjunction with Argonne National Laboratories), specification of performance parameters and catalyst requirements, development of representative component designs and manufacturing processes for these components, and development of a comprehensive bill of materials and list of purchased components. The model, data, and component designs have been refined based on comments from the Freedom Car Technical Team and fuel cell system and component developers.