Topology Optimization of Fuel Cells: an Innovative Approach for Sustainable Aviation

Abstract The imperative to meet COP 21 targets underscores the pressing need to reduce our dependence on fossil fuel-based technologies. Among the array of viable alternatives, hydrogen stands out as a compelling candidate, with applications spanning from ground vehicles to energy production and even the most challenging sectors to decarbonize, like aviation. Hydrogen’s versatility and scalability render it a subject of growing interest across various industries, but the rapid market penetration of hydrogen-related solutions is hampered by some shortcomings in the performances of the applications. For instance, the current maximum efficiency of fuel cells hovers around 60%, leaving significant room for improvement. This paper shows how topology optimization can help designers and manufacturers of fuel cells understand and improve some of the crucial features of these devices. For example, the application of topology optimization can increase the uniformity in reactant delivery, improve the cooling system and reduce the pressure losses in the manifolds. These aspects are crucial for improving the energy density of these products, increasing also their efficiency and reliability. The resulting geometries show how, with the support of topology optimization, fuel cells will be soon ready for real-world aviation applications.