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Cost-effective and flexible 3D printed SOFC stacks for commercial applications

Objective

A Solid Oxide Fuel Cell (SOFC) is a ceramic-based multilayer device that involves expensive and time-consuming multi-step manufacturing processes including tape casting, screen printing, firing, shaping and several high-temperature thermal treatments. In addition, these cells are manually assembled into stacks resulting in extra steps for joining and sealing that difficult the standardization and quality control of the final product while introducing weak parts likely to fail. Since current ceramics processing presents strong limitations in shape and extremely complex design for manufacturing (more than 100 steps), industrially fabricated SOFC cells and stacks are expensive and present low flexibility and long time to market. This is particularly relevant for the commercial segment of the stationary fuel cells market (5-400kW) that is highly heterogeneous in terms of the overall power and heat requirements and requires customization of the final product.

The main goal of the Cell3Ditor project is to develop a 3D printing technology for the industrial production of SOFC stacks by covering research and innovation in all the stages of the industrial value chain (inks formulation, 3D printer development, ceramics consolidation and system integration). All-ceramic joint-free SOFC stacks with embedded fluidics and current collection will be fabricated in a two-step process (single-step printing and sintering) to reduce in energy, materials and assembly costs while simplifying the design for manufacturing and time to market.

Compared to traditional ceramic processing, the Cell3Ditor manufacturing process presents a significantly shorter time to market (from years to months) and a cost reduction estimated in 63% with an initial investment below one third of an equivalent conventional manufacturing plant (production of 1000 units per year). The project is product-driven and involves SMEs (with proved technologies) in the entire value chain to ensure reaching TRL>6.

Field of science

  • /social sciences/economics and business/business and management/commerce
  • /engineering and technology/materials engineering/ceramics
  • /engineering and technology/mechanical engineering/manufacturing engineering/additive manufacturing
  • /engineering and technology/environmental engineering/energy and fuels/fuel cell

Call for proposal

H2020-JTI-FCH-2015-1
See other projects for this call

Funding Scheme

FCH2-RIA - Research and Innovation action

Coordinator

FUNDACIO INSTITUT DE RECERCA DE L'ENERGIA DE CATALUNYA
Address
C/ Jardins De Les Dones De Negre 1
08930 Sant Adria De Besos
Spain
Activity type
Research Organisations
EU contribution
€ 503 000

Participants (7)

DANMARKS TEKNISKE UNIVERSITET
Denmark
EU contribution
€ 372 651,25
Address
Anker Engelundsvej 1 Bygning 101 A
2800 Kgs Lyngby
Activity type
Higher or Secondary Education Establishments
FRANCISCO ALBERO SA
Spain
EU contribution
€ 250 750
Address
Rafael Barradas 19 Poligono
08908 Hospitalet De Llobregat
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
3DCERAM
France
EU contribution
€ 474 750
Address
27 Rue Du Petit Theil
87280 Limoges
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
PROMETHEAN PARTICLES LTD
United Kingdom
EU contribution
€ 248 250
Address
Nottingham Road 22-26 Stapleford
NG9 8AA Nottingham
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
UNIVERSIDAD DE LA LAGUNA
Spain
EU contribution
€ 137 200
Address
Molinos De Agua S/n
38071 La Laguna Tenerife
Activity type
Higher or Secondary Education Establishments
SAAN ENERGI AB
Sweden
EU contribution
€ 154 656,25
Address
Scheelevagen 15
223 70 Lund
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
HyGear Fuel Cell Systems B.V.
Netherlands
EU contribution
€ 39 405
Address
Westervoortsedijk 73
6802 EG Arnhem
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)