Membrane Electrode Assemblies (MEAs) are a core component of fuel cells (FCs), which are expected to be produced at large scale in order to meet the different mobility industry needs and support the market growth of FCs for these applications.

However, state-of-the-art manufacturing processes still suffer from shortcomings such as:

• Production processes manufacturing speed lagging behind the necessary capacity to meet the demand (often still utilising batch processes);
• Catalyst Coated Membrane (CCM) deposition processes cannot reach an industrial production quality;
• In-line quality control processes and technologies have limited defect detection capabilities, resulting in potential escape of defective parts to market and premature equipment failures in-service;
• Manual steps induce a loss of reproducibility and quality by allowing defects all along the different manufacturing steps;
• Recyclability by design, and associated supply chain needs, necessitate new industrial processes.

Hence, the maturity of production processes requires new developments to achieve higher production volumes and meet the stringent product quality expectations of emerging FC markets and applications (e.g., stationary applications, heavy duty road transport, maritime, rail and aviation). Considering the significant Critical Raw Material (CRM) content of state-of-the-art MEAs, development of high-volume MEA production processes should include efficient material use, together with eco-design and Life Cycle Analysis of the components and the production line.

Accordingly, project results are expected to contribute to the following expected outcomes:

• Development of innovative solutions for material supply and/or processing for catalyst layer deposition and lamination of Gas Diffusion Layer GDLs/sub-gaskets demonstrated in a MEA compatible with industrial manufacturing process with a significant volume scale-up;
• Demonstrate scale-up capability and maturity of the MEA process to produce industrial standard quality MEAs, including cycle time, yield, materials input, reliability of the production process, product reproducibility, quality control and increased control over specifications;
• Process design for recycling, including Life Cycle Assessment (LCA) and cost analysis.
• Support the development of cost competitive Proton Exchange Membrane Fuel Cell (PEMFC) components from an EU supply chain.

Project results are expected to contribute to the achievement of manufacturing KPIs including:

• Dedicated manufacturing KPIs should be used to fully quantify the maturity of a production system:
  • Yield of the manufacturing process^[1]: >90% by 2030;
  • Automation of the fabrication process: reducing to a minimum human intervention, especially manual steps should be avoided during manufacturing to improve reproducibility and repeatability;
  • Scrap rate^[2]: <5% by 2030;
  • Annual production capacity^[3]: 100 000 m² for aviation purpose and 500 000 m² for other mobility applications.

Proposals are encouraged to propose additional manufacturing KPIs to further quantify the maturity of the production system.

Produced MEAs should demonstrate high durability, power density, and low PGM loading. Reference values are:

• 30,000h in transport applications (aviation, heavy-duty trucks, rail, maritime and/or passenger vehicles) that could be demonstrated by using accelerated stress-tests;
• Power density of 1.2 W.cm-2 under standard testing conditions;
• PGM loading in MEA 0.3g/kW.

For large scale production the cost target for road and rail applications is <50€/kW in 2030.

This project aims at developing and scaling-up innovative manufacturing processes for MEAs of PEMFCs. Each step of the MEA manufacturing process should be addressed and achieve TRL 6 and MRL 4-5 by the end of the project, therefore demonstrating process technology in a relevant environment with capability to produce MEAs at a rate and characteristics mentioned. In this context, to meet the expected outcomes, the following Research and Development (R&D) activities should be addressed: the design, development, and construction of a prototype production line for MEAs, which will be tested in a relevant industrial environment to validate its performance, scalability, and ability to meet the required manufacturing specifications. Here under a detailed activities that need to be included:

• Innovative up-scaling of processes (continuous production, batch production) and processes based on outcomes of previous and current research projects (MAMA-MEA^[4], VOLUMETRIQ^[5], NIMPHEA^[6]). Addressing new techniques or innovative approaches should be considered if needed on the production line to fill the gap with previously developed processes;
• Development of known processes and innovative processes (e.g. ink-jet, spray, electrospray, slot-die coating, screen-printing) for large scale catalyst and/or microporous layer deposition. Large scale should be applied to MEAs active area relevant for the large-size unit cell of the applications considered (> 200 cm²) and high-volume production as indicated above (10000 m²/year);
• Development of methods to produce optimised large size (scale-1 for the application) MEAs and high-quality interfaces (e.g. layer-to-layer manufacturing, efficient assembling and bonding of components, additive manufacturing);
• Demonstrate the technology at scale compatible with high volume and high yield, considering challenges from an industrialisation perspective (automated process, reduced processing steps at the line, end-of-line quality control, flexibility support, design adaptability, versatility, reproducibility). Process monitoring, parts validity and control means should also be evaluated on several parts at scale;
• In-line quality control considering relevant parameters related to manufacturing targets and MEAs specifications (such as but not limited to scrap rate, catalyst loading, catalyst-coated membrane thickness…);
• The prototype pilot line should be adapted to several raw materials and components (membrane or GDL, catalysts) and able of making different compositions and properties (such as porosity and hydrophobicity).
• The prototype pilot line operational effectiveness will be validated through its capability of manufacturing several MEAs at scale 1, as requested to achieve the targeted MRL 5.
• Demonstration of expected operation vs. cost, performance, durability KPIs: representative testing and characterisation of produced MEAs in single cells and small stacks, at technologically relevant scale (active area) and in application-relevant conditions (all heavy-duty transport sectors are targeted) should be undertaken as part of the project;
• Demonstration of reliable scalability expected vs. cost, performance, durability for the various applications targeted – Assessment of progress vs SoA at beginning of project
• Application of Design for Sustainability (DfS) principles to maximise potential of recycling processes to recover CRMs and minimise environmental impact and end-of-life;
• Industrial plan should include life cycle analysis, cost analysis, intellectual property and environmental health action plan.

A cost reduction assessment should also be undertaken at the end of the project highlighting the gains brought by the new concepts developed in the project.

In addition, a fully integrated collect and recycling channel associated to the production line should be described.

Proposals should develop and bring to the market an innovative manufacturing processes of MEAs for PEMFC. The process should demonstrate high production rates in line with the future needs of European fuel cell industries. The produced MEAs should simultaneously perform at relevant KPIs of the PEMFC technology.

Proposals should involve a PEMFC and MEA manufacturer and consider regulatory context as well as safety aspects.

A pilot line should be available at the end of the project with an estimation of its full potential:

• Capacity: 2000 m²/year (or a projection for a year with higher level of maturity);
• Scrap rate: 40% (or a projection for a year with higher level of maturity).

Proposals should achieve a membrane electrode assembly production line mature enough to be qualified for industrial standards (e.g. standards depending on the applications targeted by the proposal). To do so, the proposal should include European partnerships with industrials (and their supply chain ecosystem) and academics to work on Life Cycle System Analysis, development and implementation of processes, MRL analysis (with a strong focus on the maturity of the supply chain) and propose a reliable and industry-scalable concept of MEA production. This topic is hence expected to contribute to EU competitiveness and industrial leadership by supporting a European supply chain for fuel cell components.

Consortia are encouraged to explore synergies and cooperation with Made in Europe partnership^[7] and the Zero Detect Manufacturing platform^[8].

For additional elements applicable to all topics please refer to section 2.2.3.2

Activities are expected to reach TRL 6 by the end of the project - see General Annex B

Activities are expected to start at MRL 3 and achieve MRL 5 by the end of the project - see Call management and general conditions section.

The JU estimates that an EU contribution of maximum EUR 5.00 million would allow these outcomes to be addressed appropriately.

The conditions related to this topic are provided in the chapter 2.2.3.2 of the Clean Hydrogen JU 2025 Annual Work Plan and in the General Annexes to the Horizon Europe Work Programme 2023–2025 which apply mutatis mutandis.

[1] The yield should be calculated comparing the theoretical number of MEA that should be obtained in a defined time period from a given quantity of components (membrane and catalysts) with the actual number of MEA produced during this period.

[2] The scrap rate is calculated by dividing the amount of scrap produced in a given time period by the total amount of MEA produced in that same time period.

[3] The annual production capacity means the annual nominal capacity for a facility, calculated based on operations during the 24 hours of the day for an entire year

[4] https://cordis.europa.eu/project/id/779591

[5] https://cordis.europa.eu/project/id/671465

[6] https://cordis.europa.eu/project/id/101101407

[7] https://www.effra.eu/made-in-europe-state-play/

[8] https://www.zdmp.eu/