Innovative membrane electrode assemblies for efficient and robust electrolysis systems

The membrane electrode assembly (MEA) is the electrochemical heart of electrolyzers – it determines how efficiently the central conversion reactions take place. Companies ranging from start-ups to large industrial enterprises face numerous challenges in this context: Only with a precise understanding of MEA performance parameters, degradation mechanisms, and optimization potential can robust systems be developed that are scalable and economical. Innovative material combinations and industrial manufacturing strategies are required to increase the efficiency and longevity of the MEA and form the basis for reliable and economical electrolysis systems.

Typical challenges include:

• Testing and validation of innovative materials under realistic conditions
• Need for quality-assured test procedures and analytical support
• Transition from manual MEA manufacturing to scalable, reproducible production
• Limited access to pilot plant infrastructure
• Rapid prototype development and testing
• Scale-up expertise and independent validation

Fraunhofer UMSICHT offers comprehensive research and development services for the manufacturing, and testing of membrane electrode assemblies. We support you in material screening, in scale-up, process optimization, and independent validation. Specifically, our services include:

MEA manufacturing for electrolysis processes

• Manual and semi-automated production processes for maximum flexibility
• Development and optimization of pastes and inks, including homogenization and material characterization
• Processing of our own, commercial, or customer-provided materials
• Scalable manufacturing from sheet-to-sheet processes with transferability to roll-to-roll processes

Validation of MEAs and components

• Testing and characterization of catalysts, membranes, electrodes, and porous transport layers under realistic operating conditions
• Performance characterization through validation and test series
• Flexible adaptation for different cell geometries and electrolysis concepts (PEM, AEM, BPM)
• Tests at variable temperatures and operating pressures
• Degradation tests with analysis of aging mechanisms, stability, and influencing factors (CO₂ purity, impurities, dynamic load cycling)

Analytics & consulting

• Quality controls along the entire value chain – from catalyst material to finished MEA, before and after operation
• Use of modern analysis methods such as pXRD, SEM/EDX, µCT, XRF, digital microscopy
• Process and design consulting to increase efficiency, performance, and stability
• Scientific and technical support from feasibility studies to pre-engineering and scaling

With Fraunhofer UMSICHT, you gain an experienced partner who will accompany you from the initial idea to successful implementation. The following forms of cooperation are possible:

• Directly commissioned research and development projects with clearly defined goals
• Individual project planning: Joint analysis of your problem and development of a tailor-made solution plan
• Analytics and testing support: Scientific research combined with practical testing methods and modern testing technology
• Contract manufacturing of electrodes and membrane electrode assemblies
• Component evaluation: Performance and stability tests as well as investigation of the influence of contaminants and varying gas or electrolyte quality
• Technology development: Optimization of electrodes, MEAs, and process parameters to increase efficiency and product selectivity
• Workshops and training courses: Practical training on MEA manufacturing and evaluation
• Feasibility and economic studies: Technical and economic evaluation of new materials, designs, and process routes, including scalability analysis

Example project workflow

1. Project start and goal definition: Analysis of your challenge and definition of project goals
2. Concept phase: Development of an individual project and test plan
3. Implementation: Material development, manufacturing and testing, feasibility studies if necessary
4. Evaluation and optimization: Analysis of results and adjustment of parameters
5. Completion and transfer: Documentation of results and recommendation for scaling or industrial implementation

Material and component development for electrolysis processes

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The best of both worlds: stacked catalytic layers for the electrocatalytic generation of CO in zero-gap electrolysers | RSC Sustainability

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Going from Pt to PGM-free Catalysts: Effects of Ink Compositions on PEM Water Electrolysis | ChemPhysChem

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Press it, Heat it, Twist it: A Series of Hidden Parameters for the Electrochemical CO₂ Reduction in Zero-Gap Electrolyzers | Cell Press

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Pushing the Ag-loading of CO₂ electrolyzers to the minimum via molecularly tuned environments | ScienceDirect

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Closing the carbon cycle: challenges and opportunities of CO₂ electrolyser designs in light of cross-industrial CO₂ source-sink matching in the European landscape | RSC Publishing

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