Precision Nanoparticle Generation & Coating
Overview
VSParticle has developed a pilot-scale coating system based on spark ablation technology for depositing iridium catalyst layers onto substrates for PEM hydrogen electrolyzers. This approach enables significantly reduced iridium loading while maintaining precise control over the catalyst composition and structure.
Building on its research equipment, VSParticle further developed the Pilotline 3 within the CLEANHYPRO project to achieve higher throughput and validate the technology for industrial use. The system enables coating of full-scale porous transport layers (PTLs), supporting the transition from laboratory-scale development to real-life applications.
Beyond the pilot line, VSParticle can leverage complementary deposition systems to accommodate different substrate types and requirements.
Key Characteristics & Goals
Enable high-performance catalyst layers with significantly reduced iridium loading
Small nanoparticle size and controlled porosity to maximize active surface area and catalyst efficiency
Maximize utilization of iridium through efficient generation and recovery of nanoparticles
Establish a scalable pathway from research to industrial manufacturing
Benefits & Potential
VSParticle has developed a proprietary dry-coating technique for depositing catalyst layers, validated at leading research institutes using its nanoparticle deposition systems. This technology is now available for industrial applications, enabling companies to apply these coatings on porous transport electrodes (PTEs) for their PEM stacks at full scale.
The pilot line enables higher throughput and more efficient use of materials, demonstrating that VSParticle’s spark ablation technology is ready for industrial scaling.
Compared to alternative methods such as PVD, ALD, and wet coating, VSParticle offers a one-step, solvent-free process with precise control over composition and porosity, enabling efficient use of scarce iridium through low catalyst loading while maintaining high performance.
Technical Specs
Specification | Value | Unit |
Materials | Iri, IrO2, and other conductive solids at request | |
Coating characteristics | High porosity, binding free (dry coating), uniform thickness | |
Nanoparticle size | 1 – 10 | nm |
Loading | 0.1 – 0.8 | mg/cm2 |
Loading accuracy | 0.01 – 0.02 | mg/cm2 |
Maximum substrate size | > 1500 | cm2 |
Substrate types | PTL, MPL, GDL, others at request |
