Electrolyzers are considered one of the most promising solutions for the large-scale storage of electricity generated intermittently by renewable energy sources, as well as a smart alternative for decarbonizing energy-intensive sectors. Solid oxide fuel cells and electrolysis cells (SOFCs and SOECs) have high efficiency, but their ceramic nature significantly increases their manufacturing costs while limiting complex shapes and improvements. 3D printing will improve performance while reducing manufacturing and operating costs. In fact, it has recently been shown to improve the robustness of the structure.

Solid oxide cells (SOCs) are multi-layered, ceramic-based electrochemical cells consisting of a gas-tight, ionic oxide conductive electrolyte with electrodes on both sides. The best SOC materials are yttria-stabilized zirconia for the electrolyte, YSZ-based compounds (strontium lanthanum manganite) for the oxygen electrode, and Ni-YSZ for the fuel electrode.

This year, a new SOFC system received state approval through a fast-track assessment process that accelerated its development and deployment. South Korea is investing heavily in hydrogen fuel cells as a new energy source. In September 2019, SK Engineering & Construction, a unit of South Korea’s SK Group, signed an SOFC joint venture with Bloom Energy. Doosan Corp. partnered with Ceres Power of Great Britain to develop SOFCs for commercial buildings.

Solid oxide electrolysis cells (SOECs) are also gaining attention. These highly efficient energy conversion devices (>80% LHV) offer higher production yields and lower specific electrical power than competitors. New research in 2020 demonstrated 3D-printed SLA SOAs, using laser scanning. This is also a major advancement for SOECs. In fact, it is a first step toward manufacturing a radically new generation of solid oxide cells with improved performance related to their change from a planar to a three-dimensional nature. This goes beyond the high aspect ratio of the corrugated electrolyte. The 3D-printed structural elements provide integrated functionality and improved stacking capability. Arianna Pesce and colleagues recently reported these advances in J. Mater. Chem A, 2020, DOI: 10.1039/D0TA02803G. Researchers believe that 3D printing of functional materials will revolutionize the energy sector by introducing complex shapes, more robust structures, and novel functionalities never before explored.

You can find more information in the IDTechEx report, "3D Printing Composites 2020-2030: Technology and Market Analysis" and "3D Printing Materials 2019-2029: Technology and Market Analysis".