Monolithic gyroidal solid oxide cells by additive manufacturing

Zhipeng Zhou (), Aakil R. Lalwani, Xiufu Sun, Zhihao Pan, Pouya Shahriary, Yun Xie, Yijing Shang, Javier L. Navas, Alberto Basso, Naiqi Shang, Marina Artemeva, Peyman Khajavi, Ming Chen, Victor B. Tinti, David B. Pedersen, Venkata K. Nadimpalli () and Vincenzo Esposito ()
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Zhipeng Zhou: Technical University of Denmark
Aakil R. Lalwani: Technical University of Denmark
Xiufu Sun: Technical University of Denmark
Zhihao Pan: Technical University of Denmark
Pouya Shahriary: Technical University of Denmark
Yun Xie: Technical University of Denmark
Yijing Shang: Technical University of Denmark
Javier L. Navas: Technical University of Denmark
Alberto Basso: Technical University of Denmark
Naiqi Shang: Technical University of Denmark
Marina Artemeva: Technical University of Denmark
Peyman Khajavi: Technical University of Denmark
Ming Chen: Technical University of Denmark
Victor B. Tinti: Technical University of Denmark
David B. Pedersen: Technical University of Denmark
Venkata K. Nadimpalli: Technical University of Denmark
Vincenzo Esposito: Technical University of Denmark

Nature Energy, 2025, vol. 10, issue 8, 962-970

Abstract: Abstract Solid oxide cells (SOCs) efficiently interconvert chemicals and electricity. However, they are primarily confined to 2D design and fabrication technologies. Planar SOC stacks require complex multi-material components, leading to reduced compactness and high specific weight. Here we escape the 2D paradigm and adopt a true 3D design based on triply periodic minimal surface structures, enabling superior performance on gravimetric and volumetric bases. Leveraging the resolution and accuracy of additive manufacturing, we demonstrate a monolithic, gyroidal SOC that eliminates the need for metallic interconnects and sealing components. The monolith achieves optimal spatial utilization, exceptional mass-specific indexes, a straightforward manufacturing procedure and high electrochemical and thermomechanical stability. The specific power and volumetric power density surpass 1 W g−1 and 3 W cm−3 in fuel cell mode, and the mass-index and volume-index hydrogen production rates are about 7 × 10−4 Nm3 h−1 g−1 and 2 × 10−3 Nm3 h−1 cm−3 in electrolysis mode, nearly an order of magnitude enhancement compared to planar stacks.

Date: 2025
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DOI: 10.1038/s41560-025-01811-y

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