KnitMesh Technologies has been featured in a new white paper published by the German Aerospace Center (DLR) Institute of Engineering Thermodynamics.
The study explores how the design of porous transport layers (PTLs) influences the performance of water electrolysis systems for green hydrogen production. Notably, DLR’s findings show that PTLs made from knitted wire mesh can significantly enhance system efficiency, durability, and overall cost-effectiveness.
Key Findings
In controlled single-cell tests (4 cm², 1 M KOH, 60 °C), DLR compared a KnitMesh Technologies knitted wire mesh PTL with a standard configuration. The cell using our knitted wire mesh PTL:
- Increased current density by 33%.
- Reduced cell voltage by 74 mV at 2 A cm⁻², which means lower energy use under demanding conditions.
- Delivered more even compression across the active area.
- Moved gas more effectively for faster bubble removal.
- Provided strong electrical and thermal conductivity while keeping excellent permeability.
Why Knitted Wire Mesh Excels in Hydrogen Applications
A knitted wire mesh PTL behaves like a precision-engineered spring, adapting under compression, distributing clamping forces evenly, and maintaining reliable contact with the catalyst layer. This flexibility enhances the performance and durability of the membrane electrode assembly (MEA) under real-world operating conditions.
The structure also supports efficient two-phase flow, allowing gas to escape more easily and ensuring continuous access of electrolyte to the reaction sites.
Knitted wire mesh can also be customised for porosity, thickness, and filament diameter, allowing engineers to fine-tune conductivity, permeability, and elasticity to their specific stack designs. This level of design versatility is difficult to achieve with rigid or brittle PTL materials, making knitted wire mesh an ideal choice for next-generation hydrogen electrolysers.
“This study from DLR supports what we have found in our own development work. Knitted wire mesh provides a unique combination of flexibility, conductivity, and permeability, which can deliver significant performance improvements in electrolysis,” said Craig Jones, Engineering Manager at KnitMesh Technologies. “As the hydrogen industry continues to expand, innovative materials such as ours will be essential in increasing efficiency and reducing costs throughout the value chain.”
