The global push for clean energy has intensified the development of advanced hydrogen production technologies. Among these, Proton Exchange Membrane (PEM) water electrolyzers stand out due to their high efficiency, low-temperature operation, and compatibility with renewable energy sources. However, the high cost and corrosion sensitivity of conventional anode-side Gas Diffusion Electrodes (GDEs)—typically composed of titanium meshes coated with platinum—pose significant barriers to commercialization.

This project aims to develop innovative GDEs fabricated from stainless steel SS316L using Selective Laser Melting (SLM), a metal-based additive manufacturing technique. The electrodes are designed with transitional porosity, enabling a gradual change from macro- to micro-pore structures within a single monolithic body. This novel approach replaces the conventional layered architecture of separate porous transport layers, significantly reducing contact resistance and simplifying assembly.

Following fabrication, the electrodes will be coated with platinum at three different thicknesses (0.25, 0.50, and 1.00 µm) using electron-beam physical vapor deposition (E-Beam PVD), with and without chromium adhesion layers. Electrochemical performance will be evaluated via cyclic voltammetry (CV), linear sweep voltammetry (LSV), electrochemical impedance spectroscopy (EIS), Tafel plots, and chronoamperometry. Complementary physical characterizations (SEM/EDX, XRD, AFM) will be conducted to assess surface morphology and structural stability.

The best-performing electrodes will be tested in a 5 cm² PEM electrolyzer single cell under in-situ conditions. This project is expected to lower production costs by 20–30%, improve performance through reduced ohmic losses, and demonstrate the viability of transitional porosity designs in electrochemical devices. The outcomes include high-impact journal publications, a patent application, and contributions toward scalable green hydrogen technologies.