3D printing of BZY and BZCY electrolytes for Protonic Ceramic Electrolysis Cells

Due to the negative impact of traditional energy resources on the atmosphere, there is a growing shift toward sustainable alternatives. Hydrogen has emerged as a key player as energy vector in reducing greenhouse gas emissions and storing renewable energy. In recent years, producing green hydrogen through water electrolysis with reversible electrochemical devices has become a viable solution. Among hydrogen production methods, protonic ceramic electrolysis cells (PCECs) are gaining attention for their high efficiency, adaptability, and performance at lower operating temperatures (400-700°C). Despite these advantages, challenges remain in optimizing materials and manufacturing methods to improve PCEC performance, scalability and durability. This study focuses on innovative approaches to manufacturing PCEC electrolytes using additive manufacturing (AM) techniques to enhance reliability, precision, and performance. Two AM techniques, 3D-Digital Light Processing (DLP) and Robocasting (RC), were applied to fabricate the PCEC electrolyte. Custom-formulated photocurable and robocasting slurries were developed and analysed for rheological properties, polymerization behaviour, and structural integrity. Heating stage microscopy (HSM) was used to study thermal behaviour during processing, while SEM-EDX characterization provided insights into microstructural properties. These findings contribute to advancing PCEC manufacturing, offering a pathway to adjustable, efficient, and durable energy devices for a sustainable future.