3D Printing Enabled Highly Scalable Tubular Protonic Ceramic Fuel Cells

Abstract

Protonic ceramic fuel cells (PCFCs) are clean and efficient power generation devices operating at intermediate temperatures. However, manufacturing difficulties have limited their commercialization, especially for promising tubular PCFCs. Herein, we report a cost-effective 3D printing technique for manufacturing large-area tubular PCFCs (e.g., 15.7 cm2), featured with the use of commercial raw materials, a small amount of binder, and a CO2 laser for rapid in situ drying. The technical advantages enable low-cost material preparation and efficient achievement of exemplary shape/dimension-controlled uniform microstructures in porous anode support, dense electrolyte, and porous cathode. The 3D-printed tubular PCFC (∼12.5 cm2) exhibits a power output of 2.45 W at 650 °C. Meanwhile, the long-term stability is confirmed during 200 h of operation. This novel 3D printing offers great potential to advance PCFCs from the laboratory to larger scales for realistic applications.

Recent Novel Fabrication Techniques for Proton-Conducting Solid Oxide Fuel Cells

“…Mu et al [82] developed a new laser 3D printing (L3DP) method by integrating 3D printing and laser processing. The characteristics of laser 3D printing are the use of commercial raw materials, a small amount of binder, and the use of a CO 2 laser for rapid in situ drying [83]. The in situ 3D printing laser sintering technique combines digital micro-extrusion-based 3D printing with precise and rapid laser processing, which includes sintering, drying, cutting, and polishing.…”

“…This L3DP technology not only demonstrates the potential to put PCs into practical use, but also enables the rapid direct digital fabrication of ceramic-based devices [84][85][86]. By integrating 3D printing and laser processing (e.g., rapid drying, fast sintering, precise polishing, and accurate cutting), it enables the cost-effective material preparation and efficient attainment of well-defined shape and dimension-controlled uniform microstructures in porous anode supports, dense electrolytes, and porous cathodes [83].…”

“…Zou et al [83] used the L3DP to prepare a scalable tubular PCFC. The preparation process is simple and fast.…”

“…The electrolyte is uniform and dense, without visible pinholes or cracks, and adheres well to the porous electrode without exfoliation. The cathode has a fine porosity and nanoscale grains, which facilitate rapid gas transport and a large number of three-phase boundary positions, resulting in excellent electrochemical performance [83].…”

A review of progress in proton ceramic electrochemical cells: material and structural design, coupled with value-added chemical production

“…24(f)). The PCEC achieved a high-power output of 2.45 W at 650 °C and a long-term stability of 200 h. 398 The integration of digital microextrusion and laser drying technology within the continuous printing process for fuel electrodes proved pivotal for successful preparation. 398…”