Feasibility of open source fuel cell stacks with different hydrogen storage options (23.RP2.0158) – Completed

The Objectives

The project had two objectives. The first was to scale and adapt the OSS for Australian Conditions. A test case was developed to demonstrate potential applications within local hydrogen clusters—such as Hycel (Deakin University) in Victoria—and to highlight opportunities for domestic fuel-cell manufacturing, heavy-transport decarbonisation, and remote-industry energy solutions.

A key technical aim associated with Objective 1 was the development of metallic bipolar plates (BPPs) suitable for testing within the OSS platform. Metallic BPPs were identified as more relevant to Australian use-cases than the graphite plates used in the original TUC design. The case study employred a single-cell configuration in which two flow-field plates are pressed together to form a bipolar plate. This design eliminated the need for a cooling system and allowed for the use of a single channel plate with flow paths on both sides.

To establish prototype and testing requirements, Deakin University collaborated closely with TUC. This work included

• Designing the micro-stamping process and associated tooling
• Manufacturing and commissioning the tooling within a stamping press system
• Forming metallic plates and laser-cutting them to final geometries
• Preparing the OSS platform for metallic BPP integration and supporting fuel-cell testing at TU Chemnitz (Germany)

The second objective was to compare hydrogen storage and refueling options for use with the open-source fuel cell stack.

The assessment was divided into two segments:

• Part 1: A literature review of technical maturity for cryogenic adsorption
• Part 2: A comparative techno-economic analysis of various storage methods, including Liquefied Hydrogen (LH2), Compressed Hydrogen (CH2), and Cryogenic-Compressed Adsorptive Hydrogen (CCAH2).

Results and Conclusions

Testing and evaluation at Hycel (Deaking University) delivered several key insights:

Rapid Innovation Capability – The OSS enables industry and researchers to trial emerging components and technologies within a state-of-the-art fuel-cell system, accelerating innovation cycles.

Additional Equipment Requirements – Local implementation demands specialised tools beyond the standard OSS hardware, including contact-pressure tools, sealing and gasket optimisation equipment, and leak-testing systems. The shift to metallic BPPs also highlighted the need for a high-precision laser welding system—currently unavailable in Australia—to support the transition from single-cell to multi-cell stack production.

Design Implications – Integrating metallic BPPs required notable redesign of the fuel-cell stack, increasing implementation effort. However, future component substitutions of a more conventional nature are expected to be significantly simpler.

These findings contributed to a proposed framework for supporting Australian industry access to OSS technology. It identified potential partners across Victoria, Western Australia, and other Australian states and outlined the equipment, expertise, and manufacturing capability needed. This framework will enable Australian companies to engage with and utilise the OSS platform.

The project successfully fabricated and tested an OSS fuel-cell prototype incorporating Australian-developed metallic bipolar plates. This achievement represents a major milestone for local capability building.

One outcome from Part 1 of the second objective included the identification of Metal-Organic Frameworks (MOFs) as the most promising materials for hydrogen adsorption due to their ultrahigh porosity and tunable structures. However, while MOFs offer high capacity, they currently face challenges regarding durability and high costs. Conversely, zeolites and carbons are more affordable and scalable but offer lower storage capacity. Furthermore, significant data inconsistencies exist due to varied synthesis methods and structural defects present in MOFs. The study highlights a critical need for international standardised testing protocols to ensure reliable material comparisons.

An outcome from Part 2 of the second objective was the techno-economic comparison of different hydrogen storage techniques. For Stationary Applications cost-effectiveness is heavily dictated by transport distance and storage density. For Mobile Applications hydrogen purchase costs were found to dominate lifetime expenditures.

The Future of Hydrogen Storage

Integrating mature hydrogen storage technologies with the OSS will position Australia to advance its transition toward zero-emission power systems and to become a competitive contributor to global hydrogen technology development.

Advanced Materials and Engineering – Continued research into defect-engineered materials, hybrid adsorbents, and more durable metal-organic frameworks (MOFs) will help reduce costs, improve storage performance, and bridge the maturity gap between laboratory technologies and industry adoption. Collaboration with international research groups will be essential to accelerating progress.

Infrastructure Deployment and Demonstrators – Demonstration projects—potentially hosted at Hycel or within hydrogen hubs in Victoria and Western Australia—will be critical for showcasing OSS capabilities, encouraging industry engagement, and supporting early-stage market adoption.

Strengthening Australia’s Fuel-Cell Industry – Advancement from a single-cell metallic BPP design to a full multi-cell stack—supported by rapid prototyping and advanced welding capability—will reduce barriers for Australian companies entering the hydrogen sector. This will enable the development of customised fuel-cell systems tailored to local industrial and environmental requirements.