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As part of the energy transition, fuel cells are gaining increasing importance as emission-free energy converters. Electrolyzers are also being used more frequently for the emission-free production of the required “green” hydrogen.
Fuel cells as energy converters are becoming more relevant across various fields of application. Their advantages are particularly significant in the mobility sector especially in heavy-duty transport, where their benefits quite literally “carry weight.” Compared to modern battery systems, fuel cell systems offer an energy density that is 10-100 times higher relative to system weight. This makes fuel cells a particularly attractive alternative to purely battery-electric solutions, especially in long-haul freight transport, but also in maritime and aviation sectors.
The growing demand for reliable, high-performance fuel cells is creating new challenges in industrial manufacturing. One of the most critical and sensitive steps in the production of a fuel cell or an electrolyzer is the lamination process. In this step, a proton exchange membrane, ranging from 8 to 120 micrometers in thickness, is precisely positioned within a film frame and sealed securely in place. This ensures the reliable separation of water and oxygen within the system. If not done correctly, serious functional failures may occur – including the risk of explosion.
Inside a fuel cell, complex electrochemical processes take place, but its structure follows a clear principle. The key component is the Membrane Electrode Assembly (MEA). It consists of several highly functional layers: a proton-conducting membrane coated on both sides with catalyst layers, complemented by gas diffusion layers. Within this layered structure, hydrogen and oxygen are converted into electrical energy, producing only water as the sole byproduct.
Electrolyzers resemble fuel cells in their construction but are used for hydrogen production. Unlike fuel cells, the system is flooded with water instead of gas, which results in a slightly modified design.
In the production of MEAs, ultra-thin layers must be precisely stacked. These individual layers are often only 8 micrometers thick, comparable to common plastic wrap. These layers are not only costly but also extremely sensitive to mechanical stress and contamination. Even the smallest errors in the lamination process can lead to functional failures, increased scrap rates, and significant costs. Therefore, the highest level of accuracy and repeatability is required – especially for small production volumes.
A crucial step in the production process of fuel cells is the lamination of the individual functional layers. This involves bonding electrodes, catalyst layers, and membranes into a stable functional unit. The challenge: these materials are often only a few micrometers thick, thinner than a human hair, and therefore extremely delicate.
Especially when processed manually without suitable tools, achieving consistent quality is a challenge. Wrinkles, air bubbles, or even the slightest misalignment can impair the cell’s function – resulting in material loss and high scrap rates.
Additionally, many research institutions and small to medium-sized enterprises initially produce only small quantities. The use of fully automated systems is often not economically viable at this early stage.
Manual solutions like the OPTIMA Hand laminator offer a decisive advantage: They enable error-free and reproducible lamination of sensitive layer materials by ensuring precise pressure and accurate positioning, even for small batch sizes. At the same time, the devices can be easily integrated into existing laboratory environments, forming an important bridge between research and industrial production. The functional principle of the Hand laminator is derived from high-throughput production lines. As a result, the production concept also known as the industrialization approach does not need to be redeveloped when scaling up to higher volumes.
