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DTU 3D-Printed Ceramic Fuel Cell Tops 1 W/g, Targeting Lighter Aerospace Systems

The monolithic gyroid design eliminates heavy metal parts via a five-step process.

Overview

  • DTU Energy and DTU Construct published the monolithic gyroid solid oxide cell in Nature Energy on July 18, with a News & Views describing it as a promising breakthrough.
  • The fully ceramic build removes metal parts that typically make up over 75% of system weight and is produced in just five steps without fragile seals.
  • Tests report specific power exceeding 1 watt per gram, meeting the watts-to-gram ratio researchers cite for aerospace use.
  • In electrolysis mode, the device generated hydrogen at nearly ten times the rate of conventional designs.
  • The cell withstood 100°C thermal swings and repeated mode switching without structural failure; the concept is backed by a 2024 patent and Villum P2X funding, with further material optimizations proposed.