Advancements in printed components for proton exchange membrane fuel cells: A comprehensive review

Proton Exchange Membranes (PEM) are a promising technology for fuel cells and electrolyzer cells, in line with societal goals for clean and sustainable fuel conversion and generation, respectively, in a vast field of applications. PEM fuel cell (PEMFC) technology has an important advantage for energy conversion applications, because it requires a lower operating temperature and is lighter and more compact than other technologies, which makes it ideal for portable and transportation applications. However, open issues remain to be addressed for PEMFC that hinder their widespread adoption, both on the technical side, such as too high operational temperature range, cell efficiency, and long-term stability, as well as on the industrial side with implementation issues, material and device component availability, and cost. PEM technology research usually focuses on the synthesis of novel materials such as non-noble metal catalysts and non-halogenated membranes. In parallel, developing high-throughput and cost-effective manufacturing methods for components, in particular Membrane Electrode Assembly (MEA), can also lift an important barrier to their mass production, thus contributing to the same goals and securing industrial provision. From this perspective, printing technologies such as spray coating, inkjet printing, and screen printing have emerged as promising approaches with the required precision and scalability. This review covers recent advancements and developments in advanced PEMFC technology manufacturing, with a focus on 2D printing methodologies to fabricate some or all of the MEA components. Leveraging these techniques as simplified large-area manufacturing methods for PEM technology can become a more viable and industrially attractive solution. This work presents a comparison study addressing the key progress indicators both in process and in characterization to build a working framework in which both scientists, engineers and manufacturers can collaborate toward the industrial implementation of this emergent field.