Solid oxide cells (SOC) are remarkable for their versatility. They can operate in two distinct modes: as fuel cells that convert hydrogen into electricity, and as electrolysers that produce hydrogen for energy storage. Developed with ceramic components and designed to run at high temperatures, these technologies can cut hydrogen production energy consumption by up to 25%, offering a clear efficiency advantage over conventional polymer-based cells.
At present, only a limited number of organisations worldwide have the capability to manufacture this type of cell, which is recognised for its outstanding performance and efficiency. In this context, the pioneering pilot plant, Merce Lab, has positioned itself at the forefront of the field by becoming the first laboratory globally to apply 3D printing of functional ceramics to the production of SOC cells. This approach marks a significant step forward in manufacturing methods within the sector.
One of the key strengths of 3D printing lies in its high degree of design flexibility, enabling more adaptable and optimised geometries. Additionally, the process reduces material usage and significantly decreases both the weight and the volume of the final device. As a result, the overall energy density of the systems is increased, making them especially well-suited for transport applications as well as for renewable energy storage through hydrogen production.
The technology itself is highly innovative and designed with scalability in mind. The existing pre-industrial production facility has a manufacturing output of roughly 2 MW annually. Its design allows for straightforward scaling while achieving power densities up to four times higher than those of currently available commercial solutions.
Technology Value Chain: From Inks to Validation
This pilot line encompasses the full technological value chain, organising the production workflow into five key stages:
Preparation: The first stage involves creating specialised inks used as the primary raw material.
Fabrication: The second focuses on the fabrication of the cells themselves, which constitute the fundamental building blocks of the device.
Integration: The third stage consists of manufacturing the interconnectors, which are essential components that enable proper system integration.
Assembly: This is followed by the stacking of the different elements to assemble the complete unit.
Validation: Finally, the process concludes with a comprehensive validation of the finished device to ensure it meets quality and performance standards.
This structured approach not only ensures technical robustness but also facilitates effective technology transfer to companies at both national and international levels. Furthermore, it creates favourable conditions for the development of new business models aimed at accelerating industrialisation and broader adoption of renewable hydrogen solutions.
This initiative represents a major breakthrough in renewable hydrogen technology by combining the high efficiency of SOC systems with the design flexibility of 3D-printed functional ceramics. As one of the very few actors worldwide capable of manufacturing these cells, Merce Lab demonstrates clear technological leadership.
References:
Mercelab video: https://www.youtube.com/watch?v=2QJQFtqB0sA
Atlab: https://www.atlab.es/
Partner organisation:
IREC – Institut de Recerca en Energia de CatalunyaBureau Veritas
