MAMA-MEA project addresses this by assembling a consortium with extensive knowledge and expertise of both fuel cell technology and manufacturing in the digital coating and printed electronics industry, to develop the highly innovative concept of an additive layer manufacturing (ALM) process for the edge-sealed catalyst-coated membrane (CCM). The key CCM components (anode and cathode catalyst layers, ion-conducting membrane and edge seals) will be deposited with high precision and speed, one component layer on top of the other, and just in the areas of the CCM where they are required for functionality.
Preliminary prototypes have established the feasibility of the approach, and patent applications have been filed. MAMA-MEA consortium will develop this innovative ALM process from MRL 3 to MRL 6, by integrating the CCM components into a single continuous roll-to-roll manufacturing process and validating the sealed CCMs in two stationary application PEM fuel cell demonstrators.
A key project objective is an increase in the manufacturing rate of over 10 times compared to the state-of-the-art process, whilst also increasing material utilisation to 99%, and the product quality, and thus yield, to over 95%.
Overall, sealed CCM direct materials and manufacturing costs will be reduced by up to 58% in the new CCMs. The project will also conduct comprehensive ex-situ characterisation and in-situ fuel cell performance and durability testing and provide an engineering design of an ALM sealed CCM production line, including quality control methodologies.