Polymer-based fused deposition modeling of gas diffusion layer with conductive coating for proton exchange membrane fuel cell

One of the most critical components of a proton exchange membrane (PEM) fuel cell is the gas diffusion layer (GDL). Conventional preparation methods are complex, energy-consuming, and lack design flexibility. Additive manufacturing (AM) is widely used in various fields, with the fused deposition modeling (FDM) technique being the most widely used. With AM, GDLs can be designed and printed with precise control over their structure, porosity, and thickness. Previous research by the authors has shown high electrical resistance of the FDM-printed GDL. Thus, in this study, surface modification of printed GDL was performed to enhance its performance. The FDM-printed GDL with conductive graphite coating demonstrated a desirable breaking factor (2.11 kN/m) and air permeability (326 cm³/cm²/s). Its thickness, mass, and porosity were also determined to be appropriate and customizable. The performance of the manufactured GDL was examined in an open cathode air-breathing PEM fuel cell, indicating good feasibility at room temperature (20 °C). The results show that the application of the FDM technique in GDL manufacturing has great potential to revolutionize the fuel cell industry and drive progress toward a more sustainable future.