{"id":15157,"date":"2026-04-07T07:42:44","date_gmt":"2026-04-07T07:42:44","guid":{"rendered":"https:\/\/zbt.de\/projects\/pemelyonroll-scalable-roll-to-roll-production-for-pem-electrolysis-meas\/"},"modified":"2026-04-08T11:02:34","modified_gmt":"2026-04-08T11:02:34","slug":"pemelyonroll-scalable-roll-to-roll-production-for-pem-electrolysis-meas","status":"publish","type":"project","link":"https:\/\/zbt.de\/en\/projects\/pemelyonroll-scalable-roll-to-roll-production-for-pem-electrolysis-meas\/","title":{"rendered":"PEMELYonROLL: Scalable roll-to-roll production for PEM electrolysis MEAs"},"content":{"rendered":"
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PEMELYonROLL: Scalable roll-to-roll production for PEM electrolysis MEAs<\/h1>\n

Development, optimisation and validation of a process for R2R production of high-performance CCM for PEM water electrolysis<\/h4>\n

PEMELYonROLL is developing 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 aim of the project is to transfer production processes from the laboratory to pilot and industrial scale and to systematically improve the use of materials, product quality and process robustness. <\/p>\n<\/div>\n <\/div>\n<\/section>\n

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Scaling PEM electrolysis production as a key challenge<\/h2>\n

The ramp-up of the hydrogen economy requires PEM electrolysers that are not only efficient but can also be produced economically in large quantities. This is precisely where PEMELYonROLL comes in. The project addresses the scaling of production, 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 areas. <\/p>\n

The focus is on the development of a roll-to-roll producible PEM electrolysis CCM or MEA<\/strong> with significantly reduced precious metal loading<\/strong> 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. <\/p>\n<\/div>\n<\/section>\n

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From KID formulation to scalable R2R production<\/h2>\n

A key focus of the project is the development of a fully scalable production process from laboratory development to pilot plant and industrial implementation. This includes the development of catalyst ionomer dispersions (KID)<\/strong>, direct coating, drying and the assembly of membrane electrode assemblies (MEA)<\/strong>. The project is therefore not just looking at individual materials, but at the entire production process chain. <\/p>\n

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Project partners and kick-off in Krefeld<\/h2>\n

The consortium brings together complementary expertise for this purpose. Among other things, ZBT<\/strong> takes on tasks in ink development, layer application, transferability to roll-to-roll (R2R), MEA development, assembly and testing. The Institute for Energy and Material Processes (EMPI) at the University of Duisburg-Essen<\/strong> is working on the development of the KID, analytical issues and structure-property relationships. Xaptec<\/strong> is developing the inline quality assurance and the machine learning-based evaluation. Laufenberg<\/strong> is contributing its expertise to the transfer optimisation of the R2R process, the development of the production line and the transfer of the project results into marketable roll goods. These key areas of work were presented and jointly agreed at the kick-off meeting on 16. December 2025 at Laufenberg in Krefeld<\/strong>. <\/p>\n<\/div>\n <\/div>\n

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Quality assurance, error detection and robust series production<\/h2>\n

In addition to process development, quality assurance<\/strong> is a key project objective. PEMELYonROLL is developing an inline QA system with a multi-camera system, optimised lighting and machine learning evaluation<\/strong> to detect defects at an early stage and reduce rejects. In addition, material quality, batch inspections and defect and damage analyses are systematically considered in order to reliably verify product quality. <\/p>\n

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. <\/p>\n<\/div>\n<\/section>\n

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Project information<\/h2>\n