Advances in additive manufacturing of fuel cells: A review of technologies, materials, and challenges

Fuel cells offer high-efficiency power production compared to internal combustion (IC) engines and gas/steam turbines. They are also very clean and come in several types, including PEM fuel cells, solid oxide fuel cells, direct methanol fuel cells, alkaline fuel cells, molten carbonate fuel cells, and phosphoric acid fuel cells. This diversity enables a broad market for decentralized power supply—both stationary and vehicular. In recent years, significant progress has been made in using additive manufacturing (AM) to fabricate fuel cell components such as electrolytes, electrodes, and casings. AM has revolutionised fuel cell fabrication by providing a sustainable process for producing parts with complex geometries, high material flexibility, and enhanced efficiency. This review aims to summarize the importance and current status of AM in fuel cell production. Various AM techniques (such as vat photopolymerization, material jetting, and powder bed fusion (PBF)) used in manufacturing different fuel cell components are discussed, along with recent advancements in materials and their corresponding properties. The review critically analyses the state of the art, highlighting the advantages and limitations of different techniques. Furthermore, this analysis extends to identifying suitable solutions to address challenges in fuel cell fabrication, providing valuable insights for researchers and engineers focused on clean energy production. This review article will benefit researchers interested in exploring the scope of AM in fuel cells.