Advanced Manufacturing of Flow Field Components for Cost-Effective Green Hydrogen Production

Objective

The European Union aims to produce 10 million tonnes of renewable hydrogen by 2030 to achieve climate neutrality. However, water electrolysis faces significant cost barriers, with electrolyser manufacturing representing a major deployment obstacle. Flow field components account for half of total system costs due to conventional production methods that limit design optimization. Smart Transport layer Engineering through Additive Manufacturing (STREAM) addresses this challenge by developing advanced manufacturing for electrolyser components using laser powder bed fusion. The research pursues three objectives. First, create computational models optimizing porous transport layers and bipolar plates to enhance mass transport. Second, establish process parameters for additive manufacturing of titanium components with precise control over porosity and conductivity. Third, develop testing methodologies validating component performance and predicting operational lifetime. The project employs systematic approaches combining computational design, experimental manufacturing, and performance validation. Advanced modeling guides component optimization while parameter studies establish manufacturing protocols. Electrochemical testing demonstrates reliability and establishes accelerated testing standards. The fellowship at University of Applied Sciences Technikum Wien offers access to computational software, materials characterization equipment, and electrochemical testing systems. This provides essential training in advanced manufacturing techniques, computational modeling, and project leadership skills for research careers. STREAM contributes to European Green Deal implementation and REPowerEU objectives by reducing electrolyser costs and accelerating market deployment. The research supports EU industrial competitiveness in clean energy while addressing cost barriers preventing hydrogen economy development.