Hydrogen fuel cells are known for being clean and efficient—they generate electricity while releasing only water vapor.
But despite their promise, they haven’t been widely adopted yet, mainly because they’re expensive to make.
Now, a team of Norwegian researchers may have found a solution that could help fuel cells compete with other clean technologies like electric motors.
Scientists at SINTEF, an independent research institute in Norway, have developed a much thinner and lighter version of the key components inside a hydrogen fuel cell.
Their new design could make fuel cells both cheaper and better for the environment. The findings were published in the Journal of The Electrochemical Society.
Fuel cells rely on two main components: a membrane and a catalyst. The membrane helps separate hydrogen and oxygen during energy production, while the catalyst—usually made of platinum—triggers the chemical reaction that creates electricity.
The problem is that both materials are costly and come with environmental concerns. Platinum is rare and expensive, while the membrane contains fluorinated chemicals, also known as PFAS, which are linked to pollution and health risks.
The researchers focused on reducing the amount of these materials without sacrificing performance. And they succeeded.
Their redesigned fuel cell uses 62.5% less platinum than current models, which not only lowers costs but also reduces dependence on a mineral classified by the European Union as a critical raw material. Platinum is mostly mined outside Europe and has limited global supply.
As for the membrane, they managed to slim it down by 33%. The typical membrane in fuel cells today is about 15 micrometers thick, which is already incredibly thin.
But the SINTEF team developed a new version that’s just 10 micrometers—ten times thinner than a standard sheet of printer paper. Despite being thinner, the performance of the fuel cell stayed the same.
According to lead researcher Patrick Fortin, the membrane’s performance depends on how easily protons can move across its surface and through its layers.
The study showed that once the membrane is thinner than 15 micrometers, reducing the thickness further doesn’t hurt its function because the most important resistance happens at the surface, not in the bulk of the material.
By reducing the platinum and PFAS content, the team estimates the overall cost of making a membrane could drop by up to 20%, while also lowering environmental impact.
If these innovations are applied in real-world fuel cells, the technology could become a cleaner and more affordable energy option, especially for heavy vehicles, ships, and possibly even airplanes in the future.
Source: Norwegian University of Science and Technology.
