Research Projects

High-performance test environments are needed to support the development of powerful, series-ready, high-quality fuel cell stacks. FullStackTS therefore aimed to set up and validate a test environment and develop a non-discriminatory range of tests for the fuel cell industry. At the end of the project, a test bench from MS2 Engineering for fuel cell stacks up to 200 kW with specialised measurement technology from SMART Testsolutions is available at Fraunhofer ISE for contract and collaborative research. | Duration: 01/2022 - 07/2025

In the “BI-FIT”project (Break-In for Fuel Cells Initializing and Testing), Fraunhofer ISE is investigating and optimizing the break-in process, i.e. the initial operation of the fuel cell. To this end, a fundamental understanding of the mechanisms involved is being obtained through scientific, robust analyses and research, and new break-in concepts are being developed so that the duration of the break-in can be reduced to a maximum of 60 minutes. The project is integrated into the “HyFab” project network, which is intended to create a knowledge base for the automotive and supplier industry in order to facilitate research into fuel cell production technologies. | Duration: 08/2022 - 07/2025

An important form of propulsion in the future will be powered by fuel cells. However, the development focus has shifted significantly from passenger cars to freight and heavy duty traffic. At the same time, this increases the expectation of the service life of fuel cells by a factor of five to ten. This aspect is being investigated by the FC-RAT research project coordinated by Fraunhofer ISE. The understanding of the aging processes is to be significantly expanded and deepened. | Duration: 01/2021 - 06/2024

The development of new fuel cell materials and fabrication processes requires a deep understanding of the complex interaction between the transport processes of the reactants/products, the electrochemical reaction and the microstructure of the active layers. The development of improved fuel cell models in different dimensions and their validation based on experimental data is the goal of the project. | Duration: 06/2019 - 06/2024

Currently, low-temperature PEM fuel cells, such as those used in mobility, require membranes that typically contain PFSA, a type of PFAS. The project “GIRAFFE” (Generic Investigation Regarding Alternative Fluorine-Free Electrolytes for Fuel Cells) will examine commercially available PFAS-free and low-PFAS materials, with a focus on hydrocarbon polymers. These materials are environmentally benign and could offer advantages in cost and functional merits. The aim is to evaluate the technology readiness level of these materials. | Duration: 01/2024 - 12/2027

Project in the Business Area: Hydrogen Technologies; Topic: Fuel Cell; Characterization of Fuel Cells Duration: 11/2019 - 06/2024

The »HyFaB-BW« project creates an open, flexible platform for companies in the plant engineering, automotive and supplier industries in which technologies for component production and component qualification can be researched and tested with regard to the fuel cell membrane electrode assembly. This includes further topics such as the investigation of the interrelationship between the material composition of a component or its material structure and its operating behavior. In concrete terms, the project will generate findings that will enable companies to transfer their product developments to series-ready production, depending on the application and fuel cell type. HyFaB is carried out by the Center for Solar Energy and Hydrogen Research Baden-Württemberg (ZSW) (focusing on the cell stack) and the Fraunhofer Institute for Solar Energy Systems ISE (focusing on the membrane electrode unit). | Duration: 11/2019 - 06/2023

The “HyFaB3” project is developing reference processes for the production of catalyst-coated membranes (CCM) to optimize electrolysis and fuel cell technologies. The aim is to scale the cell area, reduce the precious metal content and increase throughput rates to support the market ramp-up of CCMs.. | Duration: 01/2024 - 07/2026

The “OREO” project has established robust and reproducible processes for the production of catalyst layers for both fuel cells and electrolyzers. Fraunhofer ISE developed dispersion processes to produce catalyst inks and coating processes such as slot die, screen printing and rotary screen printing to apply the ink. Ex- and in-situ analyses were utilized to understand all the processes involved in the production of the catalyst layers. In addition, a new break-in protocol for the electrolyzer cells was developed. | Duration: 01/2021 - 12/2024

The "CORAL-HD" project developed catalyst materials optimized for performance and lifetime for use in fuel cell-powered heavy-duty vehicles. Together with project partners from industry and science, Fraunhofer ISE concentrated its research on the electrodes of the fuel cell. The focus was on characterizing the materials using innovative methods. | Duration: 03/2021 - 08/2024