{"id":10598,"date":"2025-02-10T16:12:57","date_gmt":"2025-02-10T16:12:57","guid":{"rendered":"https:\/\/prod.zbt.compositas.io\/?page_id=10598"},"modified":"2025-07-30T13:19:03","modified_gmt":"2025-07-30T13:19:03","slug":"development","status":"publish","type":"page","link":"https:\/\/zbt.de\/en\/services\/development\/","title":{"rendered":"Development"},"content":{"rendered":"
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\n \"CAD\n
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Development<\/h1>\n

From the initial material idea to system maturity \u2013 integrated development approaches for electrochemical technologies<\/h4>\n

Development work at the ZBT includes the systematic design, material development and operating strategy of electrochemical components. The aim is to optimise fuel cell and electrolysis systems<\/strong> for specific applications along their entire value chain \u2013 using established CAD tools, laboratory-based materials research and simulation-based control concepts. <\/p>\n<\/div>\n <\/div>\n<\/section>\n\n\n

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Design \/ CAD \/ Engineering<\/h2>\n

CAD-supported design methods<\/strong> are used at ZBT for the development of functional fuel cell and electrolysis components. The focus is on the geometric design of metallic and compound-based bipolar plates, taking into account fluid mechanical, thermal and manufacturing requirements. <\/p>\n<\/div>\n<\/section>\n\n\n

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3D CAD: Metallic and Compound BPP<\/h2>\n

At ZBT, the geometric design of bipolar plates<\/strong> is carried out using 3D CAD and simulation-based optimisation. The aim is to develop flow- and contact-optimised structures for metallic and compound-based designs. Relevant parameters such as media distribution, pressure loss, cooling concepts and electrical contacting are taken into account with precision. <\/p>\n

<\/br>Metallic plates also require consideration of forming limits and welding specifications, while compound BPPs allow design freedom in combination with a form-friendly design. The design is based on application-specific requirements and is iteratively refined in close coordination with material development and manufacturing technologies. <\/p>\n<\/div>\n <\/div>\n

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Material Development<\/h2>\n

The ZBT develops materials for electrochemical applications<\/strong>, including catalysts, inks, compounds and seals. The aim is to optimise chemical, electrical and mechanical properties in terms of service life, processability and function in stack operation \u2013 always tailored to the respective cell or system architecture. <\/p>\n<\/div>\n<\/section>\n\n\n

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Catalysts and Inks<\/h2>\n

At ZBT, catalysts and inks for electrochemical applications \u2013 especially for CCMs \u2013 are developed to meet specific requirements. The work includes the selection of suitable catalyst materials<\/strong>, their synthesis and the formulation of stable and processable inks. Properties such as particle size, distribution, binder content and solvent are specifically tailored to the planned coating process. <\/p>\n

<\/br>The aim is to achieve high electrochemical activity<\/strong>, good adhesion and reproducible processing. The developed ink is applied on a laboratory or pilot scale and characterised electrochemically before scaling up to series production processes. <\/p>\n<\/div>\n <\/div>\n

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Compound Materials and Sealing Formulations<\/h2>\n

The ZBT develops functionalised polymer-based materials for bipolar plates and sealing systems. The focus is on electrically conductive compounds<\/strong> consisting of a thermoplastic matrix and fillers, as well as elastomeric sealing formulations<\/strong> with defined chemical and mechanical properties. <\/p>\n

<\/br>Material development<\/strong> takes into account the requirements for conductivity, media resistance and processing, as well as compatibility with downstream processes such as injection moulding or dispenser application. Formulations are systematically varied, tested for processability in the technical centre and then characterised in terms of their electrical, thermal and chemical properties. <\/p>\n

<\/br>The aim is to achieve reliable integration into scalable manufacturing processes.<\/p>\n<\/div>\n <\/div>\n

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Controls<\/h2>\n

In the Controls division, ZBT develops operating strategies for controlling and regulating electrochemical systems<\/strong>. These include methods for increasing efficiency and detecting degradation at the MEAs, stacks and complete systems levels, with a focus on dynamic load profiles and real-world operating conditions. <\/p>\n<\/div>\n<\/section>\n\n\n

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Operating Strategies for MEA Configurations<\/h2>\n

ZBT develops customised operating strategies for membrane electrode assemblies (MEAs) that are tailored to specific operating conditions and service life tests. Parameters such as current density, temperature profile and humidity are optimised to maximise the efficiency and service<\/strong> life of the MEA. <\/p>\n

<\/br>Operating strategies are iteratively adjusted through simulation-based analysis and experimental validation. The aim is to increase the overall efficiency<\/strong> of fuel cells while minimising MEA degradation. These optimisations contribute significantly to long-term stability and reduced operating costs<\/strong>. <\/p>\n<\/div>\n <\/div>\n

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Operating Strategies for Stacks<\/h2>\n

As part of the development of fuel cell stacks, ZBT focuses on optimising operating strategies<\/strong> to ensure consistent performance and a long service life. Various parameters such as pressure, temperature and gas ratios are specifically adjusted to achieve optimum load distribution and minimal resistance. <\/p>\n

<\/br>Operating strategies are developed through detailed simulations and tests<\/strong> under real operating conditions. The aim is to maximise the efficiency of the entire system and minimise degradation mechanisms in the stack components in order to extend service life and reduce costs. <\/p>\n<\/div>\n <\/div>\n

\n \"Test\n
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Operating Strategies for Components and Complete Systems<\/h2>\n

ZBT develops holistic operating strategies for fuel cell systems that are tailored to the interaction of the individual components<\/strong>. In addition to the MEAs and stacks, interactions between system components such as balance-of-plant (BoP) and system control<\/strong> are also taken into account.<\/p>\n

The aim is to maximise the efficiency and performance of the entire system under real operating conditions. To this end, experimental tests<\/strong> and model-based simulations<\/strong> are used to develop optimal operating profiles for various load scenarios and environmental conditions. These strategies ensure the long-term reliability and cost-efficiency of the entire fuel cell system.<\/p>\n<\/div>\n <\/div>\n

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Contact<\/h3>\n

Head of Department Fuel Cells and Stacks<\/p>\n<\/div>\n

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\n Dr. J\u00f6rg Karstedt\n <\/div>\n <\/div>\n
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\n <\/svg><\/i>\n +49 203 7598-1178<\/span>\n <\/div>\n
\n <\/svg><\/i>\n \n j.karstedt@zbt.de<\/a>\n <\/span>\n <\/div>\n <\/div>\n <\/div>\n
\n \"\"\n \n \n <\/div>\n <\/a>\n <\/figure>\n <\/div>\n\n\n
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Discover more services offered by ZBT<\/h2>\n
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Production Processes<\/h4>\n

The development and production of high-performance fuel cells requires a deep understanding of complex manufacturing processes. From coating technology to component manufacturing and assembly to quality assurance, our portfolio covers all key process steps. Our interdisciplinary approach enables us to develop technologies holistically, scale them and transfer them to series production \u2013 with the highest standards of technical excellence and cost-effectiveness.<\/p>\n <\/svg><\/i>\n<\/a>\n <\/div>\n

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Measurement and Testing Procedures<\/h4>\n

ZBT offers a comprehensive portfolio of measurement and testing methods for components and systems used in hydrogen and fuel cell technology. The focus is on analytical methods for material characterisation, electrochemical testing methods, quality testing during development and investigations into ageing behaviour. <\/p>\n <\/svg><\/i>\n<\/a>\n <\/div>\n

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Consulting and studies<\/h4>\n

Whether you have initial ideas or concrete projects, we provide consulting services along the entire innovation chain: from the selection of suitable technologies, infrastructure planning and safety requirements to life cycle analysis and approval issues. Together, we analyse potential, identify relevant standards and develop scientifically sound decision-making bases. <\/p>\n <\/svg><\/i>\n<\/a>\n <\/div>\n <\/div>\n<\/section>\n","protected":false},"excerpt":{"rendered":"

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