Manufacturing of Large‐Scale Titanium‐Based Porous Transport Layers for Polymer Electrolyte Membrane Electrolysis by Tape Casting

Polymer electrolyte membrane (PEM) electrolysis is an ideal method for the direct conversion of regenerative energy into hydrogen. A key component of PEM electrolysis stacks is the porous transport layer (PTL), which is usually comprised of titanium to withstand the harsh conditions of water splitting. This present study investigates the potential of tape casting as a means of mass producing titanium transport layers in a cost‐effective way. Gas‐atomized and hydrogenation–dehydrogenation titanium powders are used as starting materials. A systematic study is conducted to find processing parameters, which can demonstrate the potential of tape casting as a means of manufacturing large‐scale porous transport layers for PEM electrolyzers. For proof of concept, the dimensions of the porous transport layer are scaled up to 470 × 470 mm 2 (at a thickness of 300 μm) and the component is successfully operated in an industrial electrolyzer under realistic conditions.