Evolution of Proton Exchange Membrane Fuel Cell Technology for Aviation Applications: A Review

This review provides a comprehensive analysis of recent advancements in proton exchange membrane fuel cell (PEMFC) technology, with a specific focus on aviation applications. Each component of the PEMFC (bipolar plates, gas flow fields, gas diffusion layers, catalyst layers, and membranes) is critically examined in the context of aerospace requirements, including high specific power, lightweight construction, and operation under varying pressure, temperature, and humidity. Key aviation-specific challenges, such as water management in microgravity-aligned configurations, oxygen transport under low ambient pressures, and thermal cycling resilience, are discussed. Material innovations such as corrosion-resistant metallic bipolar plates, nanostructured Pt-alloy catalysts, hydrophobically tuned gas diffusion layers, reinforced composite membranes, and integrated flow field–diffusion interfaces are highlighted for their relevance to flight-ready systems. System-level trade-offs─balancing durability, efficiency, and safety─are also reviewed based on recent demonstrator platforms. The review concludes by identifying critical research directions to advance PEMFC deployment in short- and medium-range aircraft with particular emphasis on improving specific power, durability under load cycling, and component multifunctionality.