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Hydrogen Economy and Climate Change: Additive Manufacturing in Perspective

Author

Listed:
  • Isaac Kwesi Nooni

    (School of Atmospheric Science and Remote Sensing, Wuxi University, Wuxi 214105, China)

  • Thywill Cephas Dzogbewu

    (Department of Mechanical and Mechatronics Engineering, Central University of Technology, Free State, Bloemfontein 9301, South Africa
    Centre for Rapid Prototyping and Manufacturing, Central University of Technology, Free State, Bloemfontein 9301, South Africa)

Abstract

The hydrogen economy stands at the forefront of the global energy transition, and additive manufacturing (AM) is increasingly recognized as a critical enabler of this transformation. AM offers unique capabilities for improving the performance and durability of hydrogen energy components through rapid prototyping, topology optimization, functional integration of cooling channels, and the fabrication of intricate, hierarchical, structured pores with precisely controlled connectivity. These features facilitate efficient heat and mass transfer, thereby improving hydrogen production, storage, and utilization efficiency. Furthermore, AM’s multi-material and functionally graded printing capability holds promise for producing components with tailored properties to mitigate hydrogen embrittlement, significantly extending operational lifespan. Collectively, these advances suggest that AM could lower manufacturing costs for hydrogen-related systems while improving performance and reliability. However, the current literature provides limited evidence on the integrated techno-economic advantages of AM in hydrogen applications, posing a significant barrier to large-scale industrial adoption. At present, the technological readiness level (TRL) of AM-based hydrogen components is estimated to be 4–5, reflecting laboratory-scale progress but underscoring the need for further development, validation and industrial-scale demonstration before commercialization can be realized.

Suggested Citation

  • Isaac Kwesi Nooni & Thywill Cephas Dzogbewu, 2025. "Hydrogen Economy and Climate Change: Additive Manufacturing in Perspective," Clean Technol., MDPI, vol. 7(4), pages 1-26, October.
    • Handle: RePEc:gam:jcltec:v:7:y:2025:i:4:p:87-:d:1767367
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    References listed on IDEAS

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    1. Yang, Gaoqiang & Mo, Jingke & Kang, Zhenye & Dohrmann, Yeshi & List, Frederick A. & Green, Johney B. & Babu, Sudarsanam S. & Zhang, Feng-Yuan, 2018. "Fully printed and integrated electrolyzer cells with additive manufacturing for high-efficiency water splitting," Applied Energy, Elsevier, vol. 215(C), pages 202-210.
    2. Asim Kumar Sarker & Abul Kalam Azad & Mohammad G. Rasul & Arun Teja Doppalapudi, 2023. "Prospect of Green Hydrogen Generation from Hybrid Renewable Energy Sources: A Review," Energies, MDPI, vol. 16(3), pages 1-17, February.
    3. Scotti, Gianmario & Kanninen, Petri & Matilainen, Ville-Pekka & Salminen, Antti & Kallio, Tanja, 2016. "Stainless steel micro fuel cells with enclosed channels by laser additive manufacturing," Energy, Elsevier, vol. 106(C), pages 475-481.
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