Exploring 3D printed components for a new MEA manufacturing process in PEMWE applications

Proton Exchange Membrane Water Electrolysis (PEMWE) represents a key technology for clean and efficient hydrogen production, aligning with global sustainability goals. Central to PEMWE's effectiveness is the Membrane Electrode Assembly (MEA), a vital component responsible for facilitating electrochemical reactions. Current manufacturing methods for MEAs, such as manual processes or automated spraying, face challenges in achieving uniform catalyst distribution and minimizing material waste. This study explores a novel approach utilizing 3D printing technology to enhance the MEA fabrication process. Specifically, a custom-designed extrusion head, equipped with interchangeable cartridges and a vacuum-assisted membrane stabilization system, enables precise and scalable deposition of catalyst ink. Early results indicate significant improvements in deposition uniformity, with ongoing optimization of ink flow control and system integration to reduce membrane deformation. This work presents a promising step toward the industrialization of more efficient, cost-effective MEA production in PEMWE applications. • Developed a 3D printing-based method for direct catalyst ink deposition on Nafion® membranes. • Designed a custom extrusion head with interchangeable cartridges for precise catalyst application. • Achieved improved catalyst layer uniformity with a 1.0 mm blade during initial trials. • Addressed challenges like ink leakage and membrane deformation with system optimizations. • Presented a scalable and material-efficient approach for MEA production in PEMWE applications.