Fraunhofer ISE Membrane electrode assembly: Processes for performance and service life

The membrane electrode assembly determines the efficiency and durability of fuel cells and electrolysers. At Fraunhofer ISE, the focus is on polymer electrolyte membranes in the low-temperature range. Instead of materials research, the focus is on developing industry-ready process chains: commercial membranes and catalyst powders are purchased, processed into MEAs, and optimized in terms of performance, cost, and service life. The electrochemical reaction level—catalyst, membrane, diffusion layers—is designed on the process side to ensure reproducible quality, high area performance, and low dispersion.

Resource efficiency means specifically reducing platinum and iridium

Conserving resources is a core objective. The use of platinum (fuel cell) and iridium (electrolysis) is to be reduced without excessively reducing the power density. The challenge: less precious metal initially costs activity. The institute addresses this conflict of objectives with additives, optimized inks, precise layer architecture, and coordinated drying and calendering steps. This results in MEAs with low precious metal loading that still achieve the required performance – and whose aging behavior is specifically improved.

Reliability through performance analyses and accelerated aging tests

Performance alone is not enough; durability is the deciding factor. That is why the team combines performance characterization with accelerated stress tests (AST) to identify degradation mechanisms at an early stage. Modeling and microstructure analysis are carried out in parallel to visualize the pore structure, water balance, and gas transport. This closed learning system—model, microstructure, process, test—shortens iterations and leads more quickly to robust process windows for different applications.

From the laboratory to roll-to-roll production of industrial MEAs

Fraunhofer's mission is to bridge the gap between basic university research and industrial implementation. Accordingly, the line has been expanded from laboratory to production scale: research funds enabled investment in roll-to-roll equipment. This manufacturing technology transfers coated semi-finished products and laminated MEAs into larger quantities – with controlled ink application, drying, sintering, and lamination parameters. The acquisition and design of such equipment requires in-depth expertise; at the institute, this infrastructure is now “ready for the factory floor” for industrial projects.

Fraunhofer ISE industrial offering: From material testing to prototype stacks

Industrial customers receive answers to practical questions: Which process chain is suitable for the product? Which equipment and which coating process make sense? Which parameters ensure quality and yield? In addition to small series on pilot lines, the institute offers prototyping up to the stack level – including the construction and testing of fuel cell stacks. Light-duty requirements with low catalyst loading are covered, as are heavy-duty profiles with high continuous load. Material manufacturers (membranes, catalysts) can test new products in realistic combinations, map performance, and verify scalability.

Fraunhofer ISE designs closed development cycle for reproducible quality and efficiency

A unique selling point is the combination of in-house MEA production, modeling, and testing. Microstructure analyses, cell/stack measurements, and process data flow into a cycle that specifically refines recipes and process steps. This creates a robust data basis that reduces technology risks and accelerates industrialization – from screening and pilot batch sizes to rolling production concepts. The institute has a complete process chain at its disposal – from ink formulation and coating to testing the finished cell. This combination allows technologies to be systematically scaled and production processes to be aligned with industrial standards at an early stage.

On the way to economical series production of fuel cells

In the long term, the focus is on economic efficiency and industrial maturity. Researchers at Fraunhofer ISE are working to reduce manufacturing costs, increase material efficiency, and further extend service life. The path clearly leads toward automated, continuous production—a decisive step for the widespread use of fuel cells in mobility, energy supply, and industry. The membrane electrode assembly remains at the heart of the technology—small, precisely manufactured, and crucial to the success of the hydrogen economy.