PEMELYonROLL – Scalable roll-to-roll manufacturing for PEM electrolysis MEAs

Development, optimisation and validation of a process for R2R production of high-performance CCM for PEM water electrolysis

In the PEMELYonROLL project, ZBT is working with its partners to develop a scalable roll-to-roll process for the production of high-performance catalyst-coated membranes (CCM) and membrane electrode assemblies (MEA) for PEM water electrolysis. The goal of the project is to scale up manufacturing processes from the laboratory to pilot and industrial scales, while systematically improving material usage, product quality, and process robustness.

Scaling PEM electrolysis production as a key challenge

To ramp up the hydrogen economy, PEM electrolysers are needed that are not only high-performance but can also be manufactured economically in large quantities. This is exactly where PEMELYonROLL comes in. The project addresses the scaling of manufacturing, a scalable MEA design, and robust and sustainable production with integrated inline quality control. In the kick-off presentation, this challenge is explicitly linked to the necessary expansion of electrolysis capacities and the resulting need for significantly larger active surfaces.

The focus is on the development of a roll-to-roll producible PEM electrolysis CCM or MEA with significantly reduced precious metal loading of iridium and platinum, high current density and high long-term stability. At the same time, the suitability for use, service life and durability of the developed MEA are to be demonstrated. PEMELYonROLL thus combines material efficiency, performance and manufacturability in a joint development approach.

From KID formulation to scalable R2R production

A key focus of the project is the development of a complete, scalable manufacturing process, from laboratory development through the pilot plant to industrial realisation. This includes the development of catalyst-ionomer dispersions (KID), direct coating, drying, and the assembly of membrane electrode assemblies (MEA). The project thus focuses not only on individual materials but on the entire manufacturing process chain.

Division of Responsibilities

To this end, the consortium brings together complementary areas of expertise.

The ZBT is responsible for tasks including ink development, coating application, roll-to-roll (R2R) transferability, MEA development, assembly, and testing.

The Institute for Energy and Materials Processes (EMPI) at the University of Duisburg-Essen is working on the development of the KID, on analytical issues, and on structure-property relationships.

Xaptec develops inline quality assurance and machine learning-based analysis.

Laufenberg contributes his expertise to optimizing the transfer process in the R2R process, setting up the production line, and translating the project results into marketable roll goods.

Further information: The processes and expertise used in the project are part of ZBT’s broad-based research and development activities in the areas of development, manufacturing, and measurement and testing methods.

Quality assurance, error detection and robust series production

In addition to process development, quality assurance is a key project objective. PEMELYonROLL is developing an inline quality assurance system featuring a multi-camera setup, optimised lighting, and machine learning analysis to recognise defects early and reduce scrap. In addition, material quality, batch inspections, and defect and damage analyses are systematically evaluated to reliably verify product quality.

In addition, critical material and process parameters are to be identified, a damage catalogue drawn up and a robust QA concept for series production derived from this. The milestones mentioned in the project planning range from specifications for material and quality assurance, stable KID formulations and inline-capable QA on a laboratory scale to the integration of inline analytics into the R2R system and a guideline for the production of high-performance MEAs via direct coating. PEMELYonROLL thus creates the basis for scalable, quality-assured and industry-oriented production of components for PEM water electrolysis.

Project information

Project acronym: PEMELYonROLL
Project title: Development, optimisation and validation of a process for R2R production of high-performance CCM for PEM water electrolysis
Implementation period: 1.10.2025 – 30.9.2028
Funding program: ERDF/JTF program NRW, Energie.IN.NRW 2021-2027
Funding reference number: EFRE-2080 1468
Project budget (total): approx. € 2.5 million
Funding amount (ZBT share): 624.147,90 €
Project partners:
- Laufenberg
- Xaptec
- Institute for Energy and Material Processes, University of Duisburg-Essen
- ZBT – The Hydrogen and Fuel Cell Center

This project is funded by the European Union.

Questions about the project?

gladly to

Wladimir Philippi

Electrochemical Components

+49 203 7598-3129

w.philippi@zbt.de

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