International Journal of Hydrogen Energy | Volume 202 | 21 January 2026 | 153053
Linda Ney, Nathalie Göttlicher, Richard Lohmann, Markus Klawitter, Jakob Hog, Neethu Philip Thombra, Zohreh Kiaee, Isabell Kegel, Jürg Schleuniger, Roman Keding
For a sustainable and environmentally friendly energy transition, the development of alternative energy conversion technologies for mobile applications is of central importance. The polymer electrolyte membrane (PEM) fuel cell with its high power density and low operating temperature is one of the most promising technologies for converting chemical energy into electrical energy.
The production of these PEM fuel cells faces the challenge of reducing costs and scaling up manufacturing processes in order to enter the market with higher production volumes. This study investigates printing technologies for the fabrication of catalyst-coated membranes in PEM fuel cells, comparing established flatbed screen printing with rotary screen printing. To the best of the authors’ knowledge, this study represents the first application of rotary screen printing technology for the fabrication of catalyst layers in PEM fuel cells. Rotary screen printing offers the intrinsic advantage of enabling intermittent coating and patterning within a continuous roll-to-roll process, thereby facilitating high-throughput production of catalyst-coated membranes (CCMs).
In addition, a proof of concept is demonstrated for the fabrication of electrode structures with line widths down to 100 μm using an industrial screen printer. These electrode structures could be employed to further optimize catalyst utilization. Electrochemical characterization of the flatbed and rotary screen-printed fuel cells revealed comparable performance; consequently, this study establishes rotary screen printing as an additional printing technology for PEM fuel cells with very high throughput potential, particularly in combination with roll-to-roll machinery.