From Catalyst Ink to PEM Fuel Cell Stack: First Full-Size Screen Printed Catalyst Layers Tested within a Generic Stack

This study presents a comprehensive investigation and research platform to introduce a production process chain from catalyst ink to a generic stack level. Screen printed catalyst layers are upscaled to meet industrial active areas of 283 cm² and decal transferred onto the polymer electrolyte membrane with a roll calender, which process parameters were optimized. Afterwards, the subgaskets and gas diffusion layers were applied, and a short stack has been assembled. For the first time, screen printed catalyst layers have been tested within a short stack of automotive size, showing the same performance as its commercial references. This sets the starting point for a successful manufacturing process and stack testing platform, which is valuable especially for CCM material and component manufacturers as well as the research community.