Hydrogen fuel cells have long been seen as a promising clean energy solution. They can produce electricity using hydrogen as fuel, with water as the only byproduct.
This makes them an attractive option for reducing pollution, especially in industries like aviation and heavy transport where batteries are often not practical.
However, despite their potential, hydrogen fuel cells have struggled to become widely used.
Now, researchers from the University of New South Wales (UNSW) have developed a new design that could help overcome one of the biggest challenges facing this technology.
Their work, published in Applied Catalysis B: Environment and Energy, shows how a small structural change can make fuel cells much more efficient and easier to use in real-world applications.
One of the main problems with hydrogen fuel cells is water buildup inside the system. As the fuel cell operates, it produces water.
Some of this water can get trapped inside the cell, blocking the flow of oxygen that is needed for the reaction to continue. When this happens, the performance of the fuel cell drops.
Current solutions often require complex systems to remove the water, which adds weight, cost, and energy use.
The UNSW team took a different approach. Instead of adding extra systems, they redesigned the internal structure of the fuel cell itself.
Using advanced engineering techniques, they created tiny channels inside the cell. These channels are extremely small—about the width of a human hair—and act like escape paths for excess water and gas.
These “lateral bypasses,” as the researchers call them, allow water to flow out before it builds up and causes problems. This simple idea has a big impact. Tests showed that the redesigned fuel cell can produce about 75% more power than traditional designs.
Another advantage of this new design is that it does not significantly increase the cost or complexity of the fuel cell.
In fact, it may even reduce the need for expensive materials like platinum, which are commonly used in fuel cells today. This could make hydrogen energy more affordable and practical for large-scale use.
The improved performance and lower cost open up exciting possibilities. Hydrogen fuel cells could be used to power airplanes, trucks, and other forms of transport that require a lot of energy. Unlike batteries, which can be heavy and take time to recharge, hydrogen systems can offer longer operating times and faster refueling.
The researchers believe that aviation could be one of the first industries to benefit. Smaller, low-altitude aircraft may soon be able to use hydrogen fuel cells to fly longer distances than battery-powered planes.
The team has already patented their design and is now working on scaling it up for commercial use. If successful, this innovation could bring hydrogen fuel cells closer to everyday use, helping create a cleaner and more sustainable energy future.
Source: University of New South Wales.
