Breakthrough in fuel cells: DLR solves long-standing durability problem of platinum catalysts
July 2, 2026 | Long-lasting electrocatalysts for fuel cells and electrolysers
Breakthrough in fuel cells: DLR solves long-standing durability problem of platinum catalysts
Flame-spray pyrolysis (FSP) for catalyst production
FSP is a versatile, resource-efficient gas-phase synthesis technique for the rapid, one-step production of complex supported catalysts. Continuous material production enables batches ranging from milligrams to kilograms without the need to adjust the process parameters.
A schematic illustration of our simplified concept for flame-spray pyrolysis, as well as the catalyst structure and its integration into the architecture of a PEM fuel cell.
Catalytic flame spray pyrolysis is a process in which a liquid or gaseous feedstock is converted into nanoparticles within a flame, with a catalyst accelerating the reaction and controlling particle formation.
Scientists at the DLR Institute of Engineering Thermodynamics have developed a new catalyst structure that significantly reduces voltage degradation at low platinum loads in fuel cells and electrolysers. The results were published in the journal Carbon Energy in June 2026.
The longevity of electrocatalysts is a decisive factor for the market ramp-up of hydrogen technology. Conventional platinum-based catalysts exhibit a significant voltage drop over their service life, especially at low loads - a problem that has so far limited the economic attractiveness of fuel cells and electrolysers.
New catalyst concept: embedded and yet active
The research team at the DLR Institute of Technical Thermodynamics is tackling this challenge with a new type of electrode called Pt-e-Cn (platinum embedded nanoscale carbon network). Platinum particles are embedded in a porous, cross-linked nanocarbon framework. This structure offers physical protection against degradation processes - such as the Ostwald ripening process or particle agglomeration - but remains fully accessible for electrochemical reactions.
The chosen manufacturing process is crucial for later scalability: The structure is produced via a flame-based rapid process that is economical and suitable for industrial scales. This distinguishes the approach from many laboratory developments that fail due to complex synthesis routes that are difficult to scale up.
Result of European research cooperation
The development is a result of the EU project SUSTAINCELL, which aims to establish a permanent and sustainable supply chain for fuel cell and electrolyser components within the EU. Within the consortium, DLR worked closely with EPFL (Lausanne, Switzerland) and the CEA (France).
Scientific publication:
The study on the Pt-e-Cn structure was published in the journal Carbon Energy in June 2026. The manuscript is accessible via the following DOI https://doi.org/10.1002/cey2.70300
Outlook
The publication lays the scientific foundation for the production of long-lasting catalyst structures. The research team expects that the flame-based process will accelerate upscaling and thus significantly advance the market entry of long-lived hydrogen technologies. Further information on the SUSTAINCELL project and research at the DLR Institute of Technical Thermodynamics is available on request.
★ Funded by the Clean Hydrogen Partnership and its members Hydrogen Europe and Hydrogen Europe Research - supported by the European Union.
Contact
Prof. Dr. rer.nat. K. Andreas Friedrich
Head of Department Electrochemical Energy Technology
