In a transformative leap for sustainable energy and aerospace technology, researchers at the Technical University of Denmark (DTU) have unveiled a pioneering approach to fuel cell design that could redefine power generation in aviation and beyond. By harnessing the power of advanced 3D printing techniques and drawing inspiration from naturally optimized geometries like coral and butterfly wings, the team has created a revolutionary solid oxide fuel cell (SOC) that amalgamates lightness with unprecedented power density, potentially charting a new course for sustainable flight and space exploration.
Traditional fuel cells, though instrumental across various industries from automotive to stationary power, have been hamstrung by their heavy, metal-reliant architectures. Metallic components, which typically constitute over 75 percent of a conventional fuel cell’s weight, impose severe limitations on mobility and application, particularly in sectors where every kilogram counts, such as aerospace. Standard approaches yield bulky stacks that lack the specific power necessary to replace fossil fuels in aviation, where batteries are simply too heavy to compete — for instance, swapping jet fuel for lithium-ion batteries results in an impractical weight increase from 70 tons up to 3,500 tons.
Confronting these immense challenges, the DTU researchers, merging expertise from DTU Energy and DTU Construct, have reimagined the SOC from the ground up by incorporating a gyroid geometry — a complex, triply periodic minimal surface (TPMS) mathematically optimized to maximize surface area within constrained volumes. This gyroidal architecture, known for its robustness, lightweight, and exceptional structural integrity, is not merely a theoretical construct but has been adapted through additive manufacturing to fabricate fully ceramic, monolithic fuel cells. This presents a marked departure from the archetypal multi-layered, metal-bound stacks that have dominated the field.
The resulting innovation, dubbed the “Monolithic Gyroidal Solid Oxide Cell,” or simply “The Monolith,” achieves a remarkable specific power exceeding one watt per gram — a metric previously unattainable in SOC technologies. This figure translates into power-to-weight ratios suitable for aviation and aerospace missions, where efficient energy density is critical. Professor Vincenzo Esposito and Senior Researcher Venkata Karthik Nadimpalli highlight this as a pivotal milestone, potentially enabling electricity-based propulsion and power systems in domains hitherto dominated exclusively by hydrocarbons.
The ceramic composition of the Monolith not only reduces weight dramatically but also alleviates the intrinsic drawbacks associated with metallic components, such as thermal expansion mismatches and seal degradation. Given the porous yet structurally optimized gyroid framework, gases can flow freely and evenly throughout the cell, enhancing reaction rates and thermal management. Moreover, the integrity of the monolithic design demonstrates impressive mechanical stability, sustaining repeated thermal cycling with temperature fluctuations exceeding 100 degrees Celsius — conditions that replicate and even surpass operational extremes expected in aerospace environments.
One of the Monolith’s most striking capabilities lies in its bidirectionality. Like conventional SOCs that can toggle between energy generation in fuel cell mode and fuel production via water electrolysis, the gyroidal cell excels in both areas. Specifically, when operated in electrolysis mode, the DTU team’s design facilitates hydrogen production at rates nearly tenfold higher than traditional ceramic fuel cells. This greatly augments the versatility and practical applications for renewable energy cycles, grid stability, and fuel generation on demand — critical components of a decarbonized energy future.
The implications for space exploration are profound. Current missions, such as NASA’s Mars Oxygen ISRU Experiment (MOXIE), employ bulky and heavy oxygen-producing stacks that weigh over six tons, challenging spacecraft payload limits and launch costs. The DTU Monolith, achieving similar functional performance at a mere 800 kilograms, could revolutionize in-situ resource utilization strategies on Mars and beyond. Lighter, more efficient electrochemical devices would dramatically reduce mission costs and increase technological feasibility for long-duration extraterrestrial operations.
Beyond novel geometry and material choice, the manufacturing process itself stands out. Where traditional SOC stacks undergo dozens of complex and energy-intensive fabrication steps, DTU researchers have condensed production to just five streamlined stages via additive manufacturing. This results not only in simplified assembly but also eliminates the need for fragile metal seals and multi-material interfaces, which are often failure points over time. This efficiency and robustness promise longer service lives and reduced maintenance costs — vital for both terrestrial and off-world applications.
While the breakthrough is impressive, the DTU team envisions further improvements. Plans include refining electrolyte layers to be thinner, thereby reducing ohmic losses and boosting overall efficiency. Cost-reduction strategies involve replacing the traditionally used platinum current collectors with more affordable metals such as silver or nickel without compromising electrical conductivity or chemical stability. Additionally, the potential for even more compact gyroidal designs may open new frontiers for miniaturized power systems in portable electronics or decentralized energy generation.
The synergetic collaboration between DTU Energy’s electrochemical expertise and DTU Construct’s proficiency in computational geometry and manufacturing exemplifies how interdisciplinary research can tackle the pressing challenges in sustainable energy technologies. Supported by the Villum P2X Accelerator grant and other prominent funding bodies, this initiative not only advances fundamental science but also charts a viable trajectory for industrial-scale adoption.
Beyond its aerospace promise, the Monolith fuel cell could impact various energy-intensive sectors, including maritime transport, data centers, and critical infrastructure power backup systems. Its high specific power and resilience to thermal and mechanical stresses make it suitable for field deployment in harsh and variable environments, fostering energy reliability and transition to green energy paradigms.
In conclusion, the DTU team’s innovative reimagining of fuel cell architecture using 3D-printed ceramic gyroid structures represents a quantum leap, paving the way for sustainable, efficient, and lightweight energy conversion technologies. As climate change and environmental concerns escalate, such technological strides offer hope for a future where clean energy solutions penetrate even the most demanding sectors of human activity, rewriting the energy playbook for the skies and the stars.
Subject of Research: Fuel cell technology advancement using gyroid ceramic architectures and additive manufacturing for enhanced power-to-weight ratios in aerospace applications.
Article Title: Monolithic gyroidal solid oxide cells by additive manufacturing
News Publication Date: 18-Jul-2025
Web References:
– https://www.nature.com/articles/s41560-025-01811-y
– http://dx.doi.org/10.1038/s41560-025-01811-y
References:
Esposito, V., Nadimpalli, V. K., et al. “Monolithic gyroidal solid oxide cells by additive manufacturing.” Nature Energy, July 2025.
Image Credits: Not provided.
Keywords
Fuel cells, Oxide fuel cells, Electrolysis, Electrochemistry, Electrochemical energy, Catalysis, Energy, Chemical engineering, Additive manufacturing, Materials engineering, Fabrication
