Investigations into 3D printing of conductive inks for electrode fabrication in PEM fuel cells using a design of experiments approach

This study focuses on the experimental relationship between 3D printing parameters and the production of electrode features for proton-exchange membrane fuel cells (PEMFCs), using a Design of Experiments (DoE) methodology. The primary objective is to improve deposition quality for PEMFCs, a factor closely linked to enhanced cell efficiency, while also ensuring scalability, reduced production time, and lower costs. The research began with the formulation of a conductive carbon-based ink, compatible with the inkjet printing device, and its initial deposition on polyethylene sheets. Key printing parameters, such as nozzle diameter, filament diameter, and printing offset, were varied within a specified range. Electrode thickness, ink deposition mass, and print uniformity were employed as response variables to identify optimal printing conditions. Image analysis through MATLAB software facilitated a precise assessment of electrode physical characteristics. After this optimization, the ink was directly printed onto Nafion®® membranes to create Membrane Electrode Assemblies (MEAs), finally verifying their surface coating thickness uniformities. These findings highlight the potential of DoE-based optimization in inkjet 3D printing as a promising avenue for sustainable production solutions in the renewable energy sector, achieving substantial reductions in production time and costs.