Development
of novel technologies for catalyst synthesis and membrane
electrode assembly (MEA) fabrication is of primary importance for
further improvement of the performance and economics of proton exchange
membrane fuel cells (PEMFCs) and proton exchange membrane water electrolyzers
(PEMWEs). While the traditional manufacturing methods are time-consuming,
energy intensive, and require many processing steps, newer vapor-based
methods provide many benefits including the development of improved
catalysts and catalyst supports, deposition of uniform thin films,
reduction of catalyst loading, and minimizing the number of manufacturing
steps. Recent publications in the field identified spray pyrolysis,
reactive spray deposition technology, chemical vapor deposition, and
atomic layer deposition as advanced vapor-based catalyst synthesis
and deposition methods used for fabrication of MEAs for PEMFCs and
PEMWEs. The MEAs fabricated via vapor-based processes have shown significant
performance improvements in comparison to the state-of-the-art MEAs,
which are attributed to better catalyst distribution, improved catalyst
supports, and controlled, uniform catalyst layer microstructures.
This review provides an overview of the vapor-based synthesis and
deposition methods currently being used for the development of PEM-based
devices. The advantages and disadvantages of these methods are critically
compared and discussed while the outlook for future development is
provided.