SparkNano, based in Eindhoven, is driving a sustainable future with its Spatial Atomic Layer Deposition (ALD) technology—a highly scalable nano-coating solution that unlocks next-gen energy applications like electrolysis, fuel cells, rechargeable batteries, and solar cells.
In this blog, we explore how SparkNano’s scalable Spatial Atomic Layer Deposition technology is powering a sustainable future—enabling breakthroughs in electrolysis and the production of green hydrogen.
What is Spatial ALD, and how does it work?
Atomic Layer Deposition (ALD) is a thin-film deposition technique (<100 nm) based on controlled chemical reactions between two gases and a substrate. Since the late 1990s, ALD has been essential in microelectronics—enabling the precise, uniform layers needed for modern devices like smartphones and computers.
SparkNano, founded in 2018 as a TNO spinoff, builds on the pioneering work of Dr. Paul Poodt, CTO and founder of SparkNano. Its Spatial ALD technology speeds up the process by separating the two gases in space, enabling continuous coating as the substrate moves. This breakthrough allows scaling with much higher throughput—up to 100x faster than traditional ALD—while maintaining the same precision. The result: lower costs, reduced use of scarce materials, and broader access to clean energy solutions.
Clean Hydrogen
Technologies that reduce costs, minimise material use, and enable widespread adoption are crucial to unlocking the full potential of clean hydrogen. Proton exchange membrane (PEM) electrolysis holds a significant share of the green hydrogen market, with the market expected to grow at over 24% annually from 2023 to 2032. PEM is favored for its efficiency, compact design, fast response, and ability to operate at lower temperatures. However, it relies on iridium as a catalyst—an element that is rare and expensive, costing 2.5 times more than gold.
SparkNano’s Spatial ALD technology addresses this by dramatically reducing iridium loading. By depositing a Spatial ALD IrO2 catalyst, iridium loading is cut by a factor of 40 or more. The iridium oxide or platinum layer is applied to the electrolyser’s porous transport layer (PTL) or gas diffusion layer (GDL) using minimal material, ensuring sufficient catalytic reactions while reducing costs.
The rising demand for iridium, driven by PEM electrolysis growth, exceeds supply, posing a barrier to scaling hydrogen production. PEM electrolysis requires about 500g of platinum group metals (PGM) per MW of capacity, while Spatial ALD reduces this to just 10g per MW. SparkNano’s technology helps ensure that demand stays within global iridium supply limits, crucial for building a sustainable hydrogen economy.
SparkNano’s machines precisely deposit materials, reducing costs and helping achieve the target of $1 per kg of green hydrogen. This breakthrough technology not only lowers the cost of PEM electrolysis plants but also alleviates supply chain and resource pressures caused by dwindling iridium supplies. Furthermore, Spatial ALD improves manufacturing efficiency by ensuring the precursor gas only contacts the substrate, reducing waste. Any unused iridium atoms are recycled for future cycles, and the technology extends the lifespan of electrolysers by fully coating the porous structure, offering protection against harsh operating conditions.
SparkNano is rapidly expanding its global footprint, selling systems worldwide and increasing production to meet growing demand. Supported by high-profile partners like Air Liquide, VDL Group manufacturers, and organisations like CLEANHYPRO, SparkNano is well-positioned to continue driving advancements in next-gen energy applications, from electrolysis to fuel cells and solar cells, all while advancing a sustainable future.
For more information about SparkNano:
Join the SparkNano Spatial ALD Hub to help drive a sustainable future and stay updated with the latest expert insights: Spatial ALD Hub – SparkNano | Spatial Atomic Layer Deposition (S-ALD)
Author
Alexander Bouman, Commercial Director at SparkNano
