Lighter, More Compact Energy Solutions with 3D-Printed Gyroidal Solid Oxide Cells

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Breakthrough in Energy Technology: 3D-Printed Solid Oxide Cells Promise Lighter, More Efficient Power

DENMARK – Researchers at the Technical University of Denmark have unveiled a groundbreaking advancement in energy technology: a three-dimensional (3D) solid oxide cell (SOC) fabricated using additive manufacturing, commonly known as 3D printing. This innovation could considerably impact industries demanding lightweight, compact, and stable power sources, particularly aerospace and automotive.

The Limitations of Conventional Solid Oxide Cells

For decades,Energy Engineers have been striving to create more efficient energy storage and conversion technologies. Existing solid oxide cells typically feature a two-dimensional (2D) design, constructed with stacked layers of materials. While functional, these 2D structures present limitations.Their size reduction is restricted, and their weight is increased due to the reliance on metallic interconnects for energy flow and component sealing.

Introducing the Gyroid-Structured 3D SOC

The research team,lead by Professor Vincenzo Esposito,has overcome these challenges by designing a SOC with a unique periodic surface structure – a gyroid. This gyroid structure, already recognized for its benefits in heat exchangers, reduces weight, enhances compactness, and boosts efficiency. By substituting metal components with an ion-conducting ceramic, the team realized the full potential of the 3D-SOC concept.

“The 3D-SOC is well-suited for applications that demand lightweight construction,compactness,and stability,such as those in the aerospace and automotive industries,” explained Professor Esposito.

How the 3D SOC Works: Fuel Cells and Electrolyzers

The newly developed 3D SOC can operate in two distinct modes.As a fuel cell, it converts chemical energy into electricity using fuels like hydrogen, methane, and carbon monoxide – a process known as “X to Power.” Conversely, in electrolysis mode, it uses electricity to split water or carbon dioxide, generating fuel gases and oxygen – termed “Power to X”.

Component	Function
Dense Ceramic Electrolyte	Conducts ions between electrodes
Porous Fuel Electrode	Facilitates fuel oxidation
Porous Oxygen Electrode	Facilitates oxygen reduction

Simplified Manufacturing process

Dr. Zhipeng Zhou, the lead author of the published research, highlighted the simplicity of the 3D SOC’s manufacturing process. Unlike conventional SOC stacks requiring the assembly of numerous components – individual cells, metallic interconnects, and sealants – the 3D-SOC is created with just 3D printing, coating, and co-sintering.

The process begins with 3D printing a monolithic ceramic frame, which incorporates the electrolyte and structural support. Later, the fuel and oxygen electrodes are coated onto the electrolyte surfaces, followed by a co-sintering process that completes the functional monolithic gyroid SOC.

“Compared to conventional SOC stack technology, the 3D-SOC has an extremely simplified manufacturing process,” Dr. Zhou stated. “The complete elimination of metallic interconnects significantly improved the stability of the SOC system and reduced its cost.”

Pro Tip: Additive manufacturing provides unprecedented design freedom, allowing for complex internal structures and optimized performance in energy conversion devices.

Scaling Up and Future Applications

The 3D design enables straightforward scalability without requiring additional components, reducing the overall weight. The increased space for the electrolyte,coupled with minimized cell size,promotes compactness. According to Dr. Venkata Nadimpalli, a corresponding author in the study, the elimination of metallic interconnects dramatically boosts system stability and reduces costs.

Potential applications are vast, ranging from NASA’s mars exploration programs, where lightweight and reliable power sources are critical, to Airbus’ advancement of solid oxide fuel cell aircraft. The unique structural properties of the 3D-SOC necessitate a re-evaluation of traditional SOC design principles, particularly concerning gas distribution and heat transport.

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Understanding Solid Oxide Cells

Solid oxide cells (SOCs) are electrochemical devices that convert chemical energy directly into electrical energy, and vice versa. They operate at high temperatures (typically 600-1000°C) and use a solid ceramic electrolyte to transport ions. their high efficiency and fuel flexibility make them attractive for various applications, including stationary power generation, transportation, and auxiliary power units.

The development of 3D-printed SOCs represents a paradigm shift in SOC technology, offering meaningful advantages over traditional 2D designs. the gyroid structure provides a large surface area for electrochemical reactions, enhancing performance and efficiency. Furthermore, the monolithic design eliminates the need for complex interconnects, reducing weight and cost.