DTU Uses Lithoz Ceramic 3D Printing to Build Gyroid Fuel Cells

Researchers at the Technical University of Denmark (DTU) have developed monolithic solid oxide fuel cells (SOFCs) with 3D printed gyroid architectures made from 8 mol% yttria-stabilized zirconia (8YSZ), achieving a power-to-weight ratio of about 1 W g⁻¹. This represents a roughly fivefold improvement over conventional planar SOFC designs, which typically deliver around 0.2 W g⁻¹.

The project, led by Professor Vincenzo Esposito at DTU Energy, utilized a Lithoz CeraFab ceramic 3D printer to create a lighter fuel cell architecture aimed at hydrogen-powered transportation applications. By eliminating conventional interconnects and sealants through a monolithic design, the approach reduces weight, minimizes thermal mismatch and mechanical stress, and improves volumetric efficiency.

The gyroid structure—a type of triply periodic minimal surface (TPMS)—enables continuous, repeating channels and walls in three dimensions, providing uniform strength in all directions. This geometry is difficult to produce with traditional ceramic processing but is readily achievable via high-resolution ceramic additive manufacturing.

To ensure gas tightness under operational conditions, the researchers combined repeated gyroid units with a sealed shell frame. Contributions from DTU Construct and Associate Professor Venkata Karthik Nadimpalli helped assess the structural stability of the thin-walled gyroid architecture under thermal and mechanical loads.

Johannes Homa, CEO of Lithoz, noted that realizing 8YSZ monolithic fuel cells with intricate gyroid geometries reduces dependence on traditional interconnect and sealing architectures inherent in stacked flat designs.

The innovation supports the development of lighter fuel cell systems for use in transportation across land, water, and air, addressing key challenges in power density and system mass for hydrogen-powered vehicles.