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Highly Durable Additively Manufactured Membrane-Free Electrolyzer.
Matthew J Whittingham1, Eric M Brack2, James Waggett1
1Faculty of Science and Engineering, Manchester Metropolitan University, Dalton Building, Chester Street, Manchester M1 5GD, Great Britian.
ACS Omega
|June 16, 2025
Summary
This study introduces a novel membrane-free water electrolyzer made entirely from 3D-printed components, including Inconel-625 electrodes. This innovative device efficiently produces hydrogen and oxygen, offering a cost-effective solution for remote gas generation.
Area of Science:
- Materials Science
- Electrochemistry
- Chemical Engineering
Background:
- Traditional water electrolyzers often rely on complex and expensive components, limiting their application in remote or resource-constrained settings.
- The development of efficient, stable, and cost-effective electrocatalysts and device architectures is crucial for advancing water electrolysis technology.
Purpose of the Study:
- To present a novel, fully additively manufactured, membrane-free water electrolyzer.
- To evaluate the electrocatalytic performance and stability of additively manufactured Inconel-625 electrodes (I-AMEs).
- To optimize electrode design using computational fluid dynamics for enhanced electrode-electrolyte interaction.
Main Methods:
- Fused filament fabrication was used to create the entire water electrolyzer device, including the anode and cathode from Inconel-625 filaments.
- Electrochemical characterization, including chronoamperometry, was performed to assess the performance and stability of the I-AMEs in acidic and alkaline electrolytes.
- Computational fluid dynamics (CFD) modeling was employed to analyze fluid flow and optimize electrode architecture.
Main Results:
- The additively manufactured Inconel-625 electrodes demonstrated efficient hydrogen and oxygen evolution reactions in various electrolytes.
- The I-AMEs exhibited excellent electrochemical stability over 80 hours of operation and 192 hours of submersion in sulfuric acid.
- The membrane-free electrolyzer produced hydrogen and oxygen at rates of 100.8 mL/h and 36 mL/h, respectively, at a low current density of 5 mA cm⁻².
Conclusions:
- Additive manufacturing offers a viable pathway for fabricating high-performance, membrane-free water electrolyzers.
- The developed I-AMEs show significant potential as durable and efficient electrocatalysts for hydrogen and oxygen production.
- This technology could enable decentralized and cost-effective hydrogen and oxygen generation in remote locations.
