⚡ 3D-Printed Gyroidal Solid Oxide Cells: Lighter, More Compact Energy Solutions

3D-Printed Gyroidal Solid Oxide Cells

The future of clean and efficient energy storage may lie in an elegant geometry: the gyroid. Researchers at the Technical University of Denmark (DTU) have developed 3D-printed gyroidal solid oxide cells (3D-SOCs) that are lighter, more compact, and more efficient than conventional two-dimensional solid oxide cells. Their work, published in Nature Energy, marks a pivotal step toward next-generation fuel cells and electrolyzers designed for aerospace, automotive, and renewable energy applications.

Solid oxide cells (SOCs) are versatile electrochemical devices that can operate in two modes: as fuel cells, converting fuels like hydrogen or methane into electricity, or as electrolyzers, splitting water or carbon dioxide to produce hydrogen, oxygen, or other useful chemicals. Traditional SOCs are stacked 2D devices relying on metallic interconnects, which add weight, increase cost, and complicate scalability.

🔬 From Flat Layers to 3D Gyroid Structures

The breakthrough comes from replacing flat, stacked structures with a monolithic gyroidal geometry — a mathematically defined, continuous 3D structure known for its strength, low weight, and high surface area. Using additive manufacturing (3D printing), the DTU team created SOCs composed entirely of ion-conducting ceramic, eliminating the need for metallic interconnects and seals.

As Professor Vincenzo Esposito, corresponding author of the study, explains: “We replace the metal with an ion-conducting ceramic, thereby realizing the 3D-SOC concept. The 3D-SOC is well-suited for applications that demand lightweight construction, compactness, and stability.”

⚡ Simplified Manufacturing, Improved Performance

Conventional SOCs require many steps: fabricating single cells, stacking them, adding metallic interconnects, and sealing components. The 3D-SOCs, by contrast, are made in a streamlined process of 3D printing, electrode coating, and co-sintering. This not only reduces complexity but also improves structural integrity and reliability.

Dr. Zhipeng Zhou, lead author of the paper, notes: “Compared to conventional SOC stack technology, the 3D-SOC has an extremely simplified manufacturing process. The complete elimination of metallic interconnects significantly improved stability and reduced cost.”

🌍 Applications in Aerospace and Beyond

The potential of gyroidal SOCs extends to a wide array of sectors:

  • Aerospace: Lightweight, compact SOCs could power aircraft like Airbus’s HYLENA SOFC program or support NASA’s Mars missions by generating oxygen and electricity in extreme environments.
  • Automotive: Integration into electric vehicles could enhance energy density while lowering overall weight, addressing range and efficiency challenges.
  • Renewable Energy: SOCs can support grid-scale energy storage and hydrogen production, enabling more effective use of intermittent solar and wind power.

From a scientific perspective, these 3D-SOCs differ fundamentally from conventional SOCs in terms of gas distribution and heat transport. This opens entirely new research pathways into optimizing their performance under real-world conditions.

📈 Looking Ahead

The researchers envision further improvements in scalability, performance, and integration. As Dr. Venkata Nadimpalli highlights, 3D-SOCs could become the backbone of advanced energy systems for both Earth and space exploration. Their distinct structure challenges established assumptions about SOC performance and design, pushing materials science and energy engineering into new territory.

🔗 Learn More

Read the original article on Tech Xplore:
https://techxplore.com/news/2025-08-3d-gyroidal-solid-oxide-cells.html

Journal Reference:
Zhipeng Zhou et al., Monolithic gyroidal solid oxide cells by additive manufacturing, Nature Energy (2025). DOI: 10.1038/s41560-025-01811-y

This article was prepared with the assistance of AI technologies.

Sponsored by PWmat (Lonxun Quantum) – a leading developer of GPU-accelerated materials simulation software for cutting-edge quantum, energy, and semiconductor research. Learn more about our solutions at: https://www.pwmat.com/en

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Stay tuned for more deep dives into energy innovation, additive manufacturing, and advanced materials reshaping the future.

#3Dprinting #solidoxidecells #fuelcells #electrolyzers #gyroidstructures #additivemanufacturing #energyinnovation #aerospaceapplications #automotiveinnovation #materialsinnovation #quantumservernetworks #pwmat

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