HYScale Technology

For economical and truly green hydrogen

HYScale is the next‑generation anion-exchange-membrane water‑electrolysis (AEMWE) platform born out of EU‑funded R&D projects NEWELY, Anione and ECO2Fuel.

By pairing critical-raw-material (CRM) free catalysts with PFAS‑free membranes and operating in a diluted alkaline environment, HYScale unlocks low-cost, low-carbon hydrogen at industrial scale.

Digital render of the HYScale final Balance of Plant (BoP). Source: HyGear

Why HYScale beats today’s electrolysers

Conventional technology pain-point

HYScale solution

High CAPEX and complex stack architecture (PEMWE)

Target system CAPEX ≈ €400 /kW through simplified, mass-producible cell design

Highly corrosive 20-30 wt % KOH (AWE)

Operates in ultra-low (≤ 0.1 M) KOH, reducing material stress and OPEX

Reliance on scarce platinum-group and iridium metals (PEMWE)

100% CRM‑free catalysts for both electrodes

PFAS‑based membranes & binders (PEMWE)

PFAS‑free AionFLX™ membranes & ionomers

Large land footprint & low current density (AWE)

>1Acm⁻² at stack level, shrinking plant size

The technology building blocks

AionFLX™ Membranes & Ionomers

Developed by CENmat; PFAS‑free, partially recycled polymer backbone
High OH⁻ conductivity and > 1,000 h durability at 0.1 M KOH without detectable degradation proofed
Manufactured up to 1,000 cm² at once with batch‑to‑batch consistency for rapid scale‑up

Advanced CRM‑Free Electrodes

Developed by CENmat: CRM-Free catalysts, catalyst inks and coating methods delivering excellent activity in near‑neutral electrolyte
Progressive up‑scaling to 400 cm² active area demonstrated, with optimised porous transport (Bekaert) layers

Cost‑Driven Stack Design

Developed by The German Aerospace Center (DLR) and Consiglio Nazione delle Ricerche (CNR): Highly efficient Cell and Stack design for high current density operation to slash CAPEX
Uses affordable bipolar plates & PTLs compatible with automated manufacturing

Anion exchange membranes and ionomers

AionFLX™ from CENmat represents a significant advancement in the field of anion exchange membrane water electrolysis (AEMWE), offering highly conductive, economical, sustainable, and durable membranes and ionomers essential for water electrolysis.

What sets AionFLX™ apart is its commitment to sustainability. The technology is based on PFAS-free and recycled polymers, significantly reducing both the carbon footprint and dependence on critical raw materials. This environmentally conscious approach makes it a standout solution in the shift toward greener hydrogen production.

In performance testing, AionFLX™ membranes and ionomers have shown exceptional durability, operating for over 1,000 hours at high current densities in ultra-low alkaline concentrations (0.1 M KOH), without signs of degradation.

CENmat is now able to produce AionFLX™ membranes in a semi-automated process at sizes up to 1,000 cm², enabling greater scalability and consistency for industrial applications.

Key highlights of AionFLX™ include

Flexibility

AionFLX™ membranes remain highly flexible in both dry and wet states, making them easy to handle and assemble in electrolyser stacks.

High conductivity and stability

Developed using a proprietary nanophase separation technique, the membranes form well-defined conductive channels that ensure efficient ion transport and lasting electrochemical performance.

Cost-effectiveness

The ionomer and membrane are manufactured from the same polymer batch, streamlining the process and significantly reducing production time and overall costs.

Electrodes upscaling

Advanced Electrodes for Scalable AEM Electrolysis play a vital role in alkaline membrane water electrolysis, directly impacting system efficiency, durability, and material sustainability. In the HYScale project, significant effort has been dedicated to develop high-performance, CRM-free electrodes optimised for use with AionFLX™ membranes.

These electrodes are designed to ensure excellent catalytic activity and chemical stability in low-concentration alkaline environments, supporting the project’s goal of delivering robust and environmentally-friendly electrolyser components.

To prepare for industrial deployment, the upscaling of electrode production is a central focus. The process is strategically structured in multiple phases to refine each aspect, from catalyst formulation to coating methods, ensuring performance consistency and manufacturing scalability. One major milestone is the production of electrodes for stacks with an active area of 400 cm², paving the way for future large-scale electrolysis systems.

Key aspects of the electrodes’ upscaling process include:

Catalyst ink upscaling

Optimising the formulation and production process to improve performance and manufacturing efficiency.

Catalyst application technique

Refining coating methods to ensure uniform and effective catalyst layers on the substrate.

PTL production

Optimised PTL structure to improve performance and durability

Scalable, Cost-Driven Stack Design

The HYScale stack is built to operate at high current densities, enabling a significant reduction in capital expenditure (CAPEX), a key metric for the commercial viability of green hydrogen production.

A defining feature of the stack design is its strong emphasis on scalability and cost-efficiency. Every component has been developed with mass production in mind, ensuring that the demonstrator is not just a research prototype but a model for real-world manufacturing.

From cell architecture to component integration, the design ensures that all parts of the stack can be produced at scale using accessible and economically sustainable processes. This positions the HYScale stack as a practical foundation for future large-scale AEM electrolysis systems.

Key highlights of the HYScale stack design include

Cost-effective components

Incorporates affordable PTLs and bipolar plates without compromising performance or corrosion resistance.

Scalability

Every element of the stack is designed for mass production, supporting industrial-scale manufacturing.

Diluted KOH operation

Optimised to work with ultra-low-concentration alkaline solutions, simplifying system design and reducing material degradation.

Ready to scale with you

Whether you are integrating hydrogen into renewable micro‑grids or developing GW‑scale green‑hydrogen hubs, HYScale offers a bankable, future‑proof route to clean H₂, without the material, safety or cost compromises of legacy technologies.