HyP3D challenge producing high-pressure hydrogen with new ceramic 3D printing technique



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The HyP3D challenge has introduced a breakthrough within the manufacturing of high-pressure hydrogen utilizing 3D printing know-how.  

This Horizon Europe-funded challenge, which incorporates collaboration from French 3D printing OEM and repair bureau 3DCeram, goals to showcase the viability of disruptive high-pressure Strong Oxide Electrolysis Cell (SOEC) know-how.

HyP3D is combining this know-how with superior ceramics 3D printing to allow environment friendly and sustainable manufacturing of high-pressure hydrogen. 

“With this groundbreaking HyP3D initiative, the power sector witnesses a convergence of 3D printing prowess and hydrogen innovation, propelling the world in direction of a extra sustainable power future,” Ceram3D acknowledged in a press launch.  

Solid Oxide Electrolysis Cells diagram. Image via HyP3DStrong Oxide Electrolysis Cells diagram. Picture by way of HyP3D.

Excessive-pressure hydrogen manufacturing utilizing 3D printing 

Central to the HyP3D challenge is the creation of compact, high-pressure standalone SOEC stacks that may convert electrical energy into compressed hydrogen. HyP3D goals to make the most of 3D printed SOEC cells to attain this. 

These cells possess a big energetic space of 70 cm2, embedded functionalities, and the capability to provide hydrogen at excessive densities exceeding 0.90A/cm2 (~1.3V) underneath circumstances of 850°C and 5+ bar strain.

This novel additive manufacturing methodology is alleged to current a “paradigm shift” away from conventional ceramics SOEC processing. The 3D printed ultra-high energy density SOEC stacks reportedly provide a 2.14kW energy output inside a compact 630 cm3 quantity. This interprets to a threefold rise in particular energy per unit quantity to three.4kW/, and a fourfold enhance in particular energy per unit mass to 1.10 kW/kg. These capabilities are mentioned to exceed any present benchmarks.     

3D printed HyP3D project component. Photo via HyP3D.3D printed SOEC cell. Picture by way of HyP3D.

HyP3D: a collaborative effort 

3DCerams’s function inside HyP3D’s work plan and methodology spans 3D printable feedstock, 3D printing parameters, and thermal remedies. 

Notably, 3DCeram has used commercially accessible YSZ powders to formulate specialised slurries for SLA 3D printing. The staff is now exploring rheological habits and conducting 3D printing checks. What’s extra, the corporate is working to design optimum 3D printing procedures, and goals to provide complex-shaped elements that mirror the ultimate cell dimensions.  

3DCeram will leverage the C1000 Flexmatic, its newest semi-automatic ceramic 3D printer, to attain these objectives. Possessing a 320 x 320 mm construct platform and two lasers, the C1000 is billed as being best for industrial clients with mass 3D printing goals. The C1000 additionally incorporates a cloth recycling station, boosting automation and lowering waste.

“The industrialization prospects supplied by the C1000 FLEXMATIC are important for the profitable completion of the challenge,” 3DCeram claims.

3DCeram can be working alongside IREC, the Catalonia Institute for Vitality Analysis, to formulate optimum 3D printing methods to make sure reliability and maximize manufacturing yield. This aligns with broader efforts to advance the hydrogen economic system, scale back time-to-market, minimize uncooked materials consumption by 76%, and decrease the preliminary funding by 42% in comparison with standard manufacturing processes.   

Hydrogen manufacturing system specialists H2B2 are additionally collaborating as a part of the HyP3D challenge. The Sevilla-based firm is alleged to be “elevating the challenge’s success” due to its power effectivity experience. Certainly, the corporate’s possession of the manufacturing pilot line reportedly streamlines the manufacturing of HyP3D cells.  

The C1000 Flexmatic and recycling station. Photo via 3DCeramThe C1000 Flexmatic 3D printer and recycling station. Picture by way of 3DCeram.

Developments in ceramic 3D printing 

This isn’t the primary time 3DCeram has been referred to as upon for its ceramic 3D printing experience. Earlier this 12 months, the corporate was chosen to be an official provider for French house propulsion producer ThurstMe.

By way of this partnership, ThrustMe goals to use the potential of 3D printed ceramics in aerospace purposes. The corporate claims that, due to its high-performance materials properties, ceramics provide a extra compact, environment friendly, and dependable resolution over conventional supplies.      

“A few of our parts are uncovered to excessive temperatures in a chemically energetic plasma setting, requiring a cloth with distinctive warmth and chemical resistance,” defined Elena Zorzolli Rossi, ThrustMe’s Product Supervisor. “Ceramics emerged as the most suitable choice on this regard, with its exceptional thermal and chemical stability.

Elsewhere, it was introduced final 12 months that Cornell College, alongside start-up Dimensional Vitality and Austrian Ceramic 3D printing firm Lithoz, had been awarded a grant to develop novel ceramics that might be used to 3D print clear power reactor elements. 

After elevating $50,000 in funding, researchers on the corporations labored to develop a novel ceramic that may deal with the excessive temperatures of thermocatalytic reactors in operation. Using 3D printing and laptop modeling, the staff claimed that it might be attainable to layer this materials into constructions, formed particularly to enhance resilience and reactor CO2 conversion charges.       

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Featured picture reveals a 3D printed SOEC cell. Picture by way of HyP3D.


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