SBIR Phase II: ADVANCING ELECTROLYZER TECHNOLOGY USING A MULTIFUNCTIONAL POROUS TRANSPORT LAYER

The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase II project is to address a critical barrier in electrolyzer technology. Hydrogen is widely recognized as essential for decarbonizing industries such as steelmaking, fertilizer production, and heavy transportation; however, today’s polymer electrolyte membrane electrolyzers rely on a porous transport layer (PTL). This project is developing a novel PTL that reduces production costs, improves electrochemical performance, and strengthens domestic supply chains. This Small Business Innovation Research (SBIR) Phase II project addresses the development of a high-efficiency, low-cost porous transport layer (PTL) for proton exchange membrane electrolyzers. Conventional PTLs, typically fabricated by sintering titanium powders or fibers, exhibit inconsistent pore structures, constrained mass transport, and high manufacturing costs. This project applies photochemical microfabrication to produce ultra-thin titanium PTLs with precisely tunable microchannels that enhance transport, oxygen removal, and electrical conductivity. Research objectives include refining PTL architecture, validating integration with existing electrolyzer components through diffusion bonding, and benchmarking performance against current state-of-the-art materials. The work will proceed through laboratory-scale validation of manufacturability, repeatability, and electrochemical performance, followed by system integration and operational testing in proton exchange membrane cells under industrially relevant conditions. By the conclusion of the project, the technology is expected to achieve readiness for large-scale deployment, providing a clear pathway to more efficient, durable, and cost-effective hydrogen production systems. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.