Researchers at the Technical University of Denmark have introduced a game-changing fabrication method for solid oxide cells (SOCs)—electrochemical devices that function as fuel cells or electrolyzers—by embracing 3D additive manufacturing to create monolithic, gyroid-structured SOCs, tells Tech Xplore.
Traditional SOCs typically rely on a 2D planar stack design, which includes multiple layers of cells, metallic interconnects, and sealants. This approach adds weight, reduces compactness, and complicates assembly. In contrast, the new gyroid 3D structure, drawing from triply periodic minimal surface geometries, is fabricated in one piece, eliminating the need for metallic components and complex seals.
The fabrication process unfolds in three key steps:
- 3D Printing: A single, continuous ceramic frame—including the electrolyte, support, and seal—is printed via additive manufacturing, achieving high resolution and geometric complexity.
- Coating: The porous fuel electrode and oxygen electrode are applied to the respective surfaces of the ceramic structure.
- Co-sintering: All layers are sintered together to form a monolithic gyroidal solid oxide cell.
This fabrication yields a sleek, integrated device with significantly improved compactness, weight reduction, and enhanced thermomechanical stability—ideal for applications in aerospace, automotive, and hydrogen generation. Performance metrics are impressive: in fuel-cell mode, the gyroid SOC achieves over 1 W per gram and 3 W per cm³, while in electrolysis mode, hydrogen production reaches ~7 × 10⁻⁴ Nm³/h per g and 2 × 10⁻³ Nm³/h per cm³—almost an order of magnitude better than planar stacks.
The 3D-printed monolithic gyroid SOC marks a breakthrough in solid oxide technology: it simplifies and streamlines fabrication, enhances performance, and opens avenues for scalable, compact energy systems.