A Novel Laser 3D Printing Method for the Advanced Manufacturing of Protonic Ceramics

Abstract

Protonic ceramics (PCs) with high proton conductivity at intermediate temperatures (300–600 °C) have attracted many applications in energy conversion and storage devices such as PC fuel/electrolysis cells, PC membrane reactors, hydrogen pump, hydrogen or water-permeable membranes, and gas sensors. One of the essential steps for fulfilling the practical utilization of these intermediate-temperature PC energy devices is the successful development of advanced manufacturing methods for cost-effectively and rapidly fabricating them with high energy density and efficiency in a customized demand. In this work, we developed a new laser 3D printing (L3DP) technique by integrating digital microextrusion-based 3D printing and precise and rapid laser processing (sintering, drying, cutting, and polishing), which showed the capability of manufacturing PCs with desired complex geometries, crystal structures, and microstructures. The L3DP method allowed the fabrication of PC parts such as pellets, cylinders, cones, films, straight/lobed tubes with sealed endings, microchannel membranes, and half cells for assembling PC energy devices. The preliminary measurement of the L3DP electrolyte film showed a high proton conductivity of ≈7 × 10−3 S/cm. This L3DP technique not only demonstrated the potential to bring the PCs into practical use but also made it possible for the rapid direct digital manufacturing of ceramic-based devices.

Materials development and prospective for protonic ceramic fuel cells

“…In realizing scale-up in PCFCs, some researchers have reported significant contributions that could aid in achieving this goal. For instance, Mu et al 231 presented a unique digital approach which integrates precise micro extrusion of 3D printing and fast laser processing for achieving several developmental processes in PCFC fabrication such as sintering, drying, cutting and polishing. Tarutin et al 232 also introduced a one-step sintering F I G U R E 1 6 RePCC operating in (A) protonic ceramic fuel cell mode and (B) protonic ceramic electrolysis mode.…”

A Comprehensive Review on Printed Electronics: A Technology Drift towards a Sustainable Future

“…Printed fuel cells based on protonic ceramics are attracting interest in clean energy and a sustainable future [ 100 , 101 , 102 ]. Furthermore, compact and printable batteries and fuel cells further provide pathways for next-generation innovators to develop cutting-edge applications across various nodes.…”

Advanced Manufacturing of Intermediate-Temperature Protonic Ceramic Electrochemical Cells

“…Although the AM of ceramics has also caught increasing attention, the successful AM of ceramic devices must solve the difficulty for achieving high accuracy due to the significant shrinkage, the difficulty for fulfilling crack-free rapid sintering due to the intrinsic brittleness, and the difficulty for depositing precise layers due to the heavy involvement of additive materials. 54 The house-made I-AMLP station (Fig. 9a) consists of X-Y and Z stages, microextruders, a CO 2 laser, a picosecond YAG laser, and a Galvano scanner.…”