Current methods for manufacturing porous transport layers (PTLs) offer limited manufacturing control over structural morphology and are inefficient in their material use. Novel multi-layer hierarchical/gradient flow fields have shown promise; however, the existing manufacturing methods have limited capabilities in creating optimal porosity gradients. Flow channels in bipolar plates influence performance efficiency but optimizing this design pattern is an ongoing research effort. Traditional methods often prove to be costly and energy intensive.

This research explores laser powder bed fusion (L-PBF), an additive manufacturing (AM) technique, as an alternative approach to PTL fabrication. L-PBF works by spreading a thin layer of metal powder across a build platform, then using a high-powered laser to selectively melt and fuse specific areas according to a digital model. After each layer is processed, the build platform lowers incrementally, a new layer of powder is spread, and the process repeats until the entire three-dimensional object is constructed layer by layer. L-PBF offers enhanced design flexibility while reducing material waste and energy consumption. AM has already demonstrated promise in electrolyser component fabrication, including bipolar plates, liquid-gas diffusion layers, and integrated transport layers.

In collaboration with the Central University of Technology, the following novel platinum–titanium electrodes have been manufactured and tested:

• Novel designs
• Metal additive manufacturing of components
• Manufacturing of 3D printed electrolyser flow fields
• Testing of electrolyser performance