CellDiagnostics – In-situ diagnostics for electrolysis and fuel cells

Fuel cell and electrolysis technologies are the key to a greenhouse gas-neutral energy supply. This requires robust, practical analyses directly in the cell: current densities, temperatures and impedances – spatially resolved and under real operating conditions. This is precisely where CellDiagnostics comes in.

Optimised cell analysis

DiLiCo engineering, the ZBT and the EST at Clausthal University of Technology are working together to develop a novel in-situ measurement system that enables spatially resolved electrochemical impedance spectroscopy (EIS) in the cell and combines it with segmented current density and temperature measurement. This makes ageing, supply and hot-spot effects visible that remain hidden with conventional ex-situ measurements.

The project is divided into three sub-projects:

  • DiLiCo: Development of a novel digital-analog interface for the integration of spatially resolved EIS measurements with an in-situ current density meter for galvanic cells
  • TU Clausthal (EST): Development of an alkaline water electrolysis cell, with spatially and half-side resolved impedance spectroscopy for in-depth characterization of cell components
  • ZBT: Development of an innovative tool for segmented current density measurement for fuel cells
A diagram illustrating the steps involved in manufacturing the segmented measuring tool

Our contribution (ZBT)

ZBT is developing a hybrid 3D printing tool (plastic + metal) as a segmented bipolar plate for PEM fuel cells. It combines flowfield, galvanic coating, segmented electrical paths and sealing technology in one component – pressure-tight, short-circuit-free and suitable for real cell structures. The approach enables precise, spatially resolved coupling directly at the membrane and adds a strong unique selling point to the DiLiCo measurement technology.

Focal points

  • Design & rapid prototyping (CAD / 3D printing), joining of the multi-component structure, HSC machining of the flowfields, electroplating, dispensing seal.
  • Test bench and validation: electrical segment conductivity, short-circuit-free, pressure-tightness and in-cell tests

Benefits
Flexible adaptation to geometries without expensive tools, faster iterations, realistic data for optimising flowfields, materials and operating strategies.

Project information

Project title
CellDiagnostics – Development of a novel in-situ measuring device for the combined recording of spatially resolved currents, temperatures and impedances on membranes for aging and operational analysis of electrolysis and fuel cells

The cooperation project is funded by the Federal Ministry for Economic Affairs and Energy as part of the central innovation program for SMEs.

Project coordination
DiLiCo engineering GmbH

Project partners

  • DiLiCo engineering GmbH
  • ZBT – The Hydrogen and Fuel Cell Center
  • Research Center for Energy Storage Technologies (EST), TU Clausthal

Project sponsor
AiF Projekt GmbH


Project duration
1. September 2025 – August 31. 2027

Funding code
KK5190510LT4

Department
ZBT – Fuel cell systems

Funding logo BMWE and ZIM

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