{"id":6834,"date":"2023-01-01T10:00:00","date_gmt":"2023-01-01T10:00:00","guid":{"rendered":"https:\/\/prod.zbt.compositas.io\/projects\/besuch-aus-uebersee-fragt-wie-kooperieren-forschungseinrichtungen-und-wirtschaft-in-deutschland\/"},"modified":"2025-08-21T10:08:06","modified_gmt":"2025-08-21T10:08:06","slug":"igf-project-no-22754-n","status":"publish","type":"project","link":"https:\/\/zbt.de\/en\/projects\/igf-project-no-22754-n\/","title":{"rendered":"Start of development: Manufacturing flexibly configurable sensor fuel cells using 3D printing and electroplating technology"},"content":{"rendered":"
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Start of development: Manufacturing flexibly configurable sensor fuel cells using 3D printing and electroplating technology<\/h1>\n
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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. <\/p>\n<\/div>\n

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Test fuel cells<\/b> 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. <\/p>\n<\/div>\n <\/div>\n

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When used as sensors, such cells support research, development and quality assurance<\/b> 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. <\/p>\n

However, Germany has a robust infrastructure of small and medium-sized companies<\/b> that can serve highly diversified markets thanks to their technological leadership. In the field of sensor cells, however, new manufacturing processes<\/b> 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. <\/p>\n<\/div>\n<\/section>\n\n\n

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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<\/span><\/strong> is leading the way here.<\/p>\n

In 3D printing, as a mouldless approach, initial processes already exist for manufacturing components suitable for fuel cells<\/span><\/strong>. 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.<\/p>\n

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<\/span><\/strong> in relation to possible harmful gas influences<\/span><\/strong>. This will provide proof of concept for the new process.<\/p>\n

Fuel Cell Systems Department<\/a><\/p>\n

Project partners:<\/b><\/p>\n