From October 26^th to 28^th, visitors can meet our team at the project stand in the EU Projects Pavillon and to learn how the team is developing the new anion exchange membrane (AEM) water electrolysis technology using CRM and PFAS-free materials and components. Meet our team: Jure Gramc, Sustainability Researcher at the University of Ljubljana and Elizaveta Kuzmina, Communication Specialist at META Group.

At the HYScale stand, visitors will discover:

• The latest progress in developing CRM and PFAS-free electrolyser components.
• Innovative manufacturing approaches designed to support large-scale deployment.
• The development of a low-CAPEX 100 kW AEM electrolyser stack.
• How HYScale contributes to the goals of the EU Hydrogen Strategy.
• Opportunities for collaboration and knowledge exchange with leading experts in the hydrogen sector.

Join the HYScale workshop | Tuesday 27 October at 11.10 am

As part of the programme, Julien Fage, Polymer Chemistry Researcher at CENMAT, will be deliver a 20-minute workshop at the EU projects Pavillon, where he will present the project’s latest technical achievements and its pathway towards industrial-scale deployment.

The workshop will highlight:

• How the team has successfully scaled up key electrolyser components and validated innovative materials, designs and manufacturing approaches through single-cell testing and operation of a 6 kW short stack.
• The development of the project’s 100 kW stack, optimised for high current-density operation and designed using affordable components compatible with automated manufacturing.

Looking ahead, the integration and long-term operation of the 100-kW system will validate the technology at TRL 5, demonstrating stable performance and controllable, low-cost manufacturing approaches that support future scale-up and broader deployment of AEM electrolysis technologies in Europe.

Register at the European Hydrogen Week.

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To bring hydrogen technologies closer to large-scale deployment, researchers need to understand how different electrolyser components behave under realistic operating conditions. In this study, the HYScale team investigated the impact of cell design, operating pressure and electrolyte management on the performance and durability of anion exchange membrane water electrolysers (AEMWEs).

After testing different material combinations and operating conditions, the researchers identified configurations that improved long-term stability and reduced degradation during operation.

Key findings:

• Nickel-based components showed better long-term stability than stainless-steel alternatives
• Electrolyte concentration strongly influenced degradation rates
• Very low electrolyte flow rates reduced performance, especially at high current densities
• Operating conditions are as important as material selection for long-term durability
• The results provide practical guidance for industrial AEM electrolyser operation

Explore the full publication here.

The post Practical design guidelines for efficient AEM water electrolysis appeared first on HYScale.

Iridium is one of the most expensive and scarce materials used in proton exchange membrane water electrolysers (PEMWEs). Finding ways to reduce the amount required is therefore essential for making hydrogen production more affordable.

In this publication, HYScale researchers developed a new catalyst design that makes more efficient use of iridium. The catalyst layer gradually organises itself during operation, creating a structure that remains stable while using significantly less iridium than conventional systems. Despite the reduced amount of catalyst, the electrolyser operated for around 2,000 hours without significant performance loss.

The results show that reducing the use of critical raw materials does not necessarily mean compromising durability, offering a promising route for future PEM electrolyser development.

Find the full publication here.

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Most research on electrolysers focuses on catalysts and membranes. This study looked at something different: the metal layer that helps water and gases move through the cell.

HYScale researchers developed a flexible nickel wire mesh that improved the contact between components inside the electrolyser and supported more efficient operation.

The study showed:

• Up to 25% higher current density compared with conventional designs
• Better distribution of pressure across the cell
• Improved water supply and gas removal
• No need for complex machined flow fields
• Stable operation demonstrated over 1,000 hours

Find the full publication here.

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In the framework of the EFCF 2025 event, the HYScale team from CNR-ITAE prepared a conference paper on optimisation of porous transport layers and interlayers, which was successfully published on ZENODO.

This study investigates how the design of electrolysers affects the efficiency and durability of flow-field-free anion exchange membrane alkaline electrolysers. Small design choices, such as the thickness of internal layers and how tightly the parts are pressed together can make a big difference, especially when the system is working hard. Thicker metal layers make the device more durable, while some materials work better at first but wear out faster over time. Overall, the study shows that better design is key to making reliable and efficient systems for producing green hydrogen.

Key findings:

1. Cell architecture strongly affects electrolyser performance and lifetime
2. Thicker nickel felt PTLs improve stability under high pressure and current
3. Mechanical compression must be carefully optimised
4. Interlayers influence both initial efficiency and degradation behaviour
5. Performance–durability trade-offs are unavoidable and must be balanced
6. Flow-field-free alkaline electrolysers are viable with proper material optimisation
7. Findings support scalable, pressurised green hydrogen production pressurised alkaline electrolysers suitable for large-scale green hydrogen production.

Explore the full paper here.

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As the demand for clean hydrogen energy continues to rise, researchers are working to make hydrogen production both more efficient and affordable. One promising approach is anion exchange membrane water electrolysis (AEMWE). This complex term translates into a simple process: produce hydrogen using renewable electricity without relying on critical raw materials such as costly precious metals. However, the performance of these electrolysers depends greatly on a component known as the porous transport layer (PTL).

From a technical point of view, the PTL is positioned between the catalyst layer and the metal plates within the electrolyser. Its role is to help water reach the reaction sites, allow oxygen gas to escape, conduct electricity, and distribute mechanical pressure evenly. If the PTL is poorly designed, trapped gas bubbles can block reaction surfaces, electrical contact may weaken, and the cell can wear out more quickly.

The HYScale researchers investigated a new PTL made from knitted wire mesh. Unlike rigid or foam-based PTLs, the knitted structure behaves like a spring, allowing it to compress evenly during assembly. This flexibility ensures better contact between layers, reduces the risk of membrane damage, and improves the flow of gases and liquid through the system.

When this knitted PTL was added to a standard AEMWE cell:

• The hydrogen production rate (current density) increased by 33%
• The cell required less voltage at high operating power, improving efficiency
• Gas removal and water movement became easier
• Mechanical stress was distributed more evenly, improving durability

The knitted PTL can be produced at a relatively low cost, making it a practical improvement for future hydrogen technologies. This innovation will also support the EU’s development by fostering a competitive, sustainable hydrogen industry and contributing to energy independence and the green transition.

The design of the PTL is led by the German Aerospace Center (DLR), partner of the HYScale project.

Find the full publication here.

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The HYScale team is happy to announce a series of technical breakthroughs that bring cost competitive, industrial scale green hydrogen production a decisive step closer to reality.

At the core of every low‑temperature water‑electrolysis system lies the membrane, a critical component for efficiency, safety, and scalability. HYScale coordinator Cutting‑Edge Nanomaterials GmbH (CENmat) has now successfully upscaled the synthesis and casting of its proprietary AionFLX anion exchange membranes (AEMs).

The new process delivers:

• dramatically reduced hydrogen permeability, resolving a long-standing performance bottleneck in AEM electrolysis.
• batch volumes sufficient for a 100 kW stack, eliminating membrane supply as a scale up constraint.

“We have moved beyond laboratory production; membranes are no longer the bottleneck,” said Dr. Julien Fage, polymer chemist and project coordinator at CENmat. “This scalability opens the door to multi‑kilowatt and soon multi‑megawatt systems.”

Building on the membrane advance, HYScale partners have fabricated large area, critical-raw-material free catalyst coated substrates (CCSs) for both anode and cathode, ensuring that all primary stack materials are available at industrial scale and meet stringent performance targets.

6 kW short stack validates integrated design

To verify real world functionality, Nicola Briguglio, PhD Material Engineer at the National Research Council of Italy (CNR-ITAE) designed, built, and operated with his team a 6 kW AEM short stack using the new membranes and CCSs.

The stack demonstrated stable operation across a wide range of temperatures, and current densities; proof that HYScale’s materials can be combined into robust, application ready membrane electrode assemblies (MEAs).

Design of 100 kW demonstrator completed

Leveraging data from the short stack tests, the German Aerospace Center (DLR) has finalised the digital design of a 100 kW HYScale stack demonstrator.

The model details dimensioning and material selection, providing a firm blueprint for construction and paving the way to Technology Readiness Level 5 (TRL 5).

“HYScale is uniquely positioned to deliver scalable, mass‑manufacturable solutions for green hydrogen,” said Jagoda Manss‑Chmielarz, R&D engineer at DLR. “Our focus is not only on better materials, but on making them work in real‑life production environments.”

HYScale’s integrated approach accelerates Europe’s transition toward affordable green hydrogen, supporting the EU’s climate and energy goals.

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