Start of development: Manufacturing flexibly configurable sensor fuel cells using 3D printing and electroplating technology

ZBT is working with partners to develop a process for the economical production of sensor fuel cells in small batches using 3D printing and electroplating technology. Such cells are used in the development of fuel cell systems.

Test fuel cells with a reduced active area serve as central testing, inspection and monitoring elements in material development and prototype construction of components for fuel cell systems. In this way, they help to establish the hydrogen infrastructure.

When used as sensors, such cells support research, development and quality assurance under real operating conditions. As consumables, they must be flexible in terms of shape and quantity, inexpensive to manufacture and easy to replace and handle. Currently, there are no commercially available fuel cells that are functionally suitable for such sensor tasks. Production is not a lucrative business for large companies due to high material and development costs.

However, Germany has a robust infrastructure of small and medium-sized companies that can serve highly diversified markets thanks to their technological leadership. In the field of sensor cells, however, new manufacturing processes are needed that are flexible in terms of form factors and quantities. Only then will it be possible to develop and manufacture such cells under realistic cost scenarios for the widest possible range of applications.

In this project, which has now been launched, the ZBT is working with the Research Institute for Precious Metals and Metal Chemistry (fem) and the Institute for Microstructure Technology at the Karlsruhe Institute of Technology (IMT-KIT) to develop such a flexible manufacturing process for producing different test and sensor cells. A combination of 3D printing and electroplating technology is leading the way here.

In 3D printing, as a mouldless approach, initial processes already exist for manufacturing components suitable for fuel cells. The aim now is to develop a post-processing and electroplating process control system that can be used to add defined, electrically conductive areas to the 3D-printed plastic products.

We will then assemble these functional samples as sensor cells and operate them in test chambers for material development in fuel cell technology in order to observe their voltage signals in relation to possible harmful gas influences. This will provide proof of concept for the new process.

Fuel Cell Systems Department

Project partners:

AiF project information:

IGF project no.: 22754 N
Short topic: Sensor cell
Duration: 01.01.2023 – 31.12.2024

Image collection

Work program of the R&D partners for the process development (click to enlarge)

Early CAD model of the central sensor cell component in contact with the MEA (click to enlarge)

Further projects

1. July, 2025

OptiCold – Safe cold start for fuel cells in mobile applications

OptiCold develops materials, cell architectures and operating strategies to enable PEM fuel cells to start safely and without damage even at temperatures as low as -25 °C. The aim is to provide robust, durable and practical solutions, especially for mobile heavy-duty applications.

1. July, 2025

FLOWMEX – More efficient fuel cells through systematically improved water management

Researchers want to significantly improve water management in fuel cells. Using model-based and experimental methods, they are developing a simulation tool that realistically depicts the transport of liquid water in gas diffusion layers and flow field channels.

1. July, 2025

Interface – Microstructured Bipolar Plates for Greater Power Density and Service Life

Using innovative laser-based microstructuring, this research project optimises the interface between the bipolar plate and the gas diffusion layer in fuel cells. This improves water flow and reduces electrical contact resistance, resulting in a performance increase of up to 30% and a significantly longer service life.