Development and Characterization of a PTFE-Based Electrochemical Cell Prototype

This work reports the design, fabrication, and functional evaluation of a PTFE-based electrochemical cell prototype engineered for applications involving corrosive environments and high-purity requirements. The design was developed and optimized using SolidWorks® software to minimize reagent consumption and maximize structural efficiency. The prototype was manufactured through conventional machining and incorporated concentric O-ring seals to enable localized and scalable electrochemical etching. Functional validation using crystalline silicon substrates and a HF:ethanol electrolyte confirmed the cell’s sealing integrity, chemical resistance, and suitability for synthesizing porous silicon with high reproducibility. The prototype demonstrated durability over repeated anodization cycles, underscoring its potential for both research and industrial applications. A comparative analysis of electrochemical cell types highlighted PTFE’s superior chemical stability, while acknowledging its cost and manufacturing constraints. Future directions include the development of hybrid PTFE/graphene composites and modular systems to enhance conductivity, reduce cost, and enable broader applicability in advanced electrochemical processes.