Coral-inspired New 3D printed fuel cell could power lighter jets

Researchers at the Technical University of Denmark have developed a novel, lightweight fuel cell called the Monolithic Gyroidal Solid Oxide Cell (The Monolith), inspired by coral structures and manufactured using 3D printing. This fully ceramic fuel cell eliminates heavy metal components that typically constitute over 75% of conventional fuel cells' weight, resulting in a device that produces over one watt per gram—an unprecedented power-to-weight ratio suitable for aerospace applications. Its gyroid-based architecture maximizes surface area, enhances gas flow, improves heat distribution, and increases mechanical stability. The manufacturing process is simplified to just five steps, avoiding fragile seals and multiple materials, which enhances durability and longevity. The Monolith fuel cell demonstrates remarkable resilience, withstanding extreme temperature fluctuations of 100°C and repeated switching between power-generating and power-storing modes without structural failure. It also produces hydrogen at nearly ten times the rate of standard models during electrolysis. These features make it a promising technology for aerospace and space missions, where