Comprehensive engineering analysis of PEMFC gas diffusion layers: simulation-based evaluation of four groundbreaking structural modifications

• Proposed four innovative structural modifications for PEMFC gas diffusion layers to enhance performance metrics. • Achieved a 15% improvement in peak power density and a 12% increase in oxygen transport efficiency. • Demonstrated superior water management, reducing flooding risks with an 8.3 mg/s water removal rate. • Improved thermal stability with temperature gradients maintained within ±3°C under high load conditions. • Provided an integrated simulation-based analysis linking GDL design to efficiency, reliability, and scalability. Optimization of Proton Exchange Membrane Fuel Cells (PEMFC) remains essential for sustainable energy technology progress because it tackles efficiency limitations while enhancing reliability and reducing system scalability barriers. The study examines how Gas Diffusion Layers respond to specific structural modifications such as tailored pore size distribution and optimized channel geometry along with enhanced hydrophobicity and microporous coating integration. The research examined PEMFC performance-determining factors like oxygen transport and water management through assessments of these modified structures. Simulation models demonstrated important performance improvements in new modifications of Gas Diffusion Layers. The optimized design reached oxygen transport of 95% and water removal reached 8.3 mg/s when operated at 0.6 A/cm² maintaining superior performance metrics compared to baseline levels which achieved 82% oxygen transport and 6.1mg/s water removal. The implemented modifications represented thoughtful solutions to optimize reactant diffusion while improving water removal effectiveness thus addressing historical operating challenges like flooding and oxygen starvation. The work investigates these innovations through a thorough assessment revealing a comprehensive connection between their design effects on operational stability and energy efficiency. These enhanced GDL configurations demonstrate their capacity to boost PEMFC performance through scientific data which supports additional development for renewable energy applications.