Slot-die coating for fuel cells and electrolyzers

The production of high-performance fuel cells and electrolyzers is a complex process involving sensitive materials and extreme precision requirements. Achieving the perfect balance of conductivity, porosity, and durability remains a significant hurdle in current research and production environments.

• Catalyst cost and utilization: The high cost of precious metal catalysts, such as Platinum or Iridium, means any non-uniformity or material waste significantly impacts the economic viability of the device.
• Variable slurry rheology: Catalyst inks often have complex flow behaviors that can lead to edge defects, non-uniform thickness, or clogging during the deposition process.
• Drying and porosity tuning: Improper drying kinetics can cause “mud-cracking” or pore collapse, which directly undermines electrochemical activity and long-term durability.
• Interface adhesion: Maintaining strong, durable adhesion between functional layers under the thermal and humid cycling of operational use is critical to prevent delamination.
• Membrane sensitivity: Thin polymer electrolyte membranes are susceptible to swelling or wrinkling when exposed to solvents or high temperatures during coating, leading to device failure.
• Scaling lab-scale results: Traditional benchtop methods often fail to reproduce the same film properties—such as uniform particle dispersion—when moving to pilot or industrial production volumes.

Slot-die technology provides a robust, engineered solution to the complex hurdles of hydrogen technology manufacturing. By replacing manual deposition with software-controlled precision, FOM systems ensure that every layer meets the exact specifications required for high-efficiency energy conversion.

• Pre-metered material control: Precision pumps and locked flow rates eliminate material waste and ensure 100% catalyst utilization, directly addressing high precious-metal costs.
• Advanced rheology handling: Specialized slot-die heads and internal shim geometries are engineered to handle complex ink viscosities without edge beading or striping defects.
• Programmed drying profiles: Staged drying—using IR or hot-air—enables fine-tuning of drying kinetics to prevent mud-cracking and maintain the ideal pore structure for gas transport.
• Engineered interface durability: Fine gap control and optimized ink-to-substrate interactions improve bond strength between functional layers, preventing delamination during humid cycling.
• Membrane-safe substrate handling: Vacuum-assisted heating and non-contact deposition protect thin, sensitive electrolyte membranes from mechanical stress, swelling, and wrinkling.
• Seamless scale-up potential: FOM platforms utilize identical coating principles from benchtop to pilot scale, ensuring a stable “process window” is directly transferable to industrial production.

Our lab scale machines

Built for fast-paced research, our lab tools create perfectly even layers with very little material waste. They are easy to set up and adjust, making them perfect for testing new materials quickly without wasting expensive inks.

These machines fit easily into gloveboxes or cleanrooms and save your protocols to ensure the same results every time, or do structured testing of different parameters. Because the process is so precise, the “recipe” you perfect in the lab is immediately ready to be scaled up for larger pre-pilot and pilot scale.

Our pre-pilot and pilot scale

Step up to wider widths and faster speeds without the typical scaling risks. By using the same slot-die heads and software as our lab tools, these platforms ensure a seamless transition from the bench to the pilot line. This continuity allows you to lock in your settings and build confidence as you scale your research from small samples to larger rolls.

Pilot scale

The FOM moduloR2R offers reliable roll-to-roll coating with precise control and customizable drying for perfect, defect-free results. You can increase your width and speed without changing your original settings. This allows you to move smoothly from testing your process to producing larger batches with total confidence.

FOM’s Tensor coating software turns coating expertise into repeatable, scalable recipes. A clean, guided user interface takes you from setup to run with recipe-based control and storage to reuse coating protocols and test coating parameters in a structured way. The same intuitive workflow spans research tools and pilot lines, helping you scale by width and throughput without reworking your process. Advanced options—such as sequences, drying/profile management, web handling, and tension control.

Why it matters

• Save time with easy setup and reusable recipes.
• Get the same results every time with locked settings and history tracking.
• Scale with ease by using familiar software and protocols as you move from the lab to the pilot line.

At FOM Technologies, we are more than just an equipment provider—we are a team of scientists dedicated to your success. We host the largest team of experts in our industry to act as your true knowledge partner, helping you bridge the gap between lab-scale discoveries and pilot-scale success.

Our training and research services provide you with direct access to our leading scientists. Whether you are a new user or a veteran researcher, you will work side-by-side with our application experts to sharpen your skills, solve technical hurdles, and master the art of slot-die coating.

How our experts support your research

• Work directly with our scientists: Collaborate with our expert team to design a custom research plan that addresses your unique material challenges.
• Live, expert-led training: Every training session is a private, live-guided experience led by a FOM scientist, whether it happens online or onsite at your facility.
• Professional research services: Our scientists can execute research at the FOM laboratory on your behalf, providing you with professionally coated samples and optimized process data.
• 1-on-1 expert consultation: Use our “Book a scientist” service for direct, hourly access to our team to troubleshoot specific issues or improve your material performance.
• Hands-on technology demos: Experience a live coating process at our laboratory, guided by our experts to help you understand the full potential of slot-die technology.