3D Printing to Enable Self-Breathing Fuel Cells.

Area of Science:

• Materials Science
• Electrochemistry
• Mechanical Engineering

Background:

• Effective reactant gas distribution and water removal are crucial for fuel cell performance.
• Bipolar plates are key components in polymer electrolyte membrane fuel cells (PEMFCs), influencing overall efficiency, size, cost, and weight.
• Current bipolar plate designs face challenges with fluid management, hydrogen leaks, and water flooding.

Purpose of the Study:

• To explore the use of photoresin 3D printing for fabricating novel bipolar plates for self-breathing fuel cell stacks.
• To assess the performance of fuel cell stacks utilizing these 3D-printed bipolar plates.
• To demonstrate a cost-effective and size-reducing manufacturing approach for fuel cells.

Main Methods:

• Fabrication of bipolar plates using photoresin 3D printing technology.
• Assembly of a 12-cell self-breathing polymer electrolyte membrane fuel cell stack.
• Performance testing of the fuel cell stack under ambient conditions (25°C and 20% relative humidity).

Main Results:

• The 3D-printed bipolar plates enabled the fabrication of monoblock shapes, resolving issues like hydrogen leaks and water flooding.
• The 12-cell self-breathing PEMFC stack achieved a power density of 0.3 W/cm².
• This performance is superior to previously reported self-breathing fuel cell designs.

Conclusions:

• Photoresin 3D printing offers a viable method for manufacturing advanced bipolar plates for PEMFCs.
• This approach significantly improves fuel cell performance and addresses critical fluid management challenges.
• 3D printing presents a promising pathway for cost-effective and compact fuel cell manufacturing, particularly for portable applications.