Porous Electrode Optimization for PEMFCs Using 3D Printing Technology
Authors: Elwan Hosni , Niblett Daniel , Mamlouk Mohamed 
Published: February 2024

Proton Exchange Membrane Fuel Cells (PEMFCs) represent a class of fuel cells that transform the chemical energy of fuels, ideally hydrogen and oxygen, into electrical power. Utilized in diverse applications, PEMFCs power vehicles and supply backup energy to buildings. The core of a PEMFC is the membrane electrode assembly (MEA), composed of a polymer electrolyte membrane, an anode, and a cathode. Oxygen, protons, and electrons merge at the cathode, forming water. One challenge PEMFCs face is water-induced cathode flooding at low temperatures, a consequence of the electrochemical reaction's water accumulation. This reduces the oxygen supply, potentially leading to decreased cell performance or even failure. This issue can have substantial undesired consequences, as PEMFCs depend on oxygen availability at the cathode to generate electricity.
Gas Diffusion Layers (GDLs) serve as critical PEMFC components, providing porous structures that facilitate reactant access to the catalyst layer and enabling electron flow through the external circuit. GDLs also offer structural support and promote reactant distribution across the membrane surface. Water accumulation in the cathode may cause pore clogging within the GDL, restricting reactant flow, and reducing cell performance. Additionally, water build-up increases pressure drop across the GDL, hindering reactant access to the catalyst layer and diminishing fuel cell efficiency.
Three-dimensional (3D) printing has emerged as a potential technique for fabricating GDLs in PEMFCs. 3D printing enables the creation of GDLs with ordered pore size structures, offering a more uniform surface than traditional GDLs with randomly oriented fibres. This uniformity enhances reactant distribution across the membrane surface and mitigates water accumulation risks. In addition, to prevent cathode flooding, 3D printed GDLs are immersed in PTFE solution to increase hydrophobicity.
This talk delves into the creation and evaluation of 3D printed carbonized GDLs for PEMFC implementation. A desktop 3D printer constructed a polymer framework, which was subsequently carbonized in a high-temperature tube furnace. Isothermal thermogravimetric analysis (TGA) tests were performed to identify weight change across a temperature range of 30-900 °C under an N2 atmosphere, optimizing the carbonization step to reduce structural distortion and increase electrical conductivity.
The 3D printed GDLs displayed pore size diameters spanning 80 to 120 μm and fibre radii of 20-30 μm. The 3D printing technique produced GDLs characterized by a consistent, planar structure without blocked pores that are normally caused by excess resin residue. Electrical conductivity assessments were conducted on the carbonized specimens, and tensile and compression tests measured their mechanical properties.
GDLs possessing minimal pore sizes and thicknesses were integrated into membrane electrode assemblies (MEAs) and examined in low-temperature PEMFCs. Diverse spraying methodologies were investigated, involving either the catalyst being sprayed onto the 3D printed GDL or the membrane receiving a catalyst coating. Commercial MEAs, comprising Nafion membranes and platinum electrodes, acted as benchmarks for MEAs featuring 3D printed GDLs. Furthermore, the current challenges facing 3D printed GDLs, including material selection, production consistency, compatibility with other PEMFC components, costs, and scaling up are highlighted in the talk.
These findings underscore the promise of 3D printed carbonized GDLs in boosting PEMFC performance, showing their potential as a cost-effective and proficient substitute for conventional carbon paper based GDLs.

Figure 1