Optimizing Drying Parameters for Crack‐Free Catalyst Layers in PEM Fuel Cell Production

The selection of drying parameters critically affects final product properties in many applications, yet remains insufficiently explored for catalyst layer fabrication in polymer electrolyte membrane fuel cells and electrolyzers. During catalyst-coated membrane production, drying conditions strongly influence the macro- and microstructure of porous catalyst layers. Crack formation, which may occur during processing as well as operation, is a key factor limiting system lifetime. Given the wide range of commercial materials and ongoing material development, a mechanistic understanding of crack formation and particularly its control through process parameters rather than ink modification is essential. This study investigates the influence of temperature, airflow, and drying air preloading on crack area and morphology. Through a systematic control of drying parameters, crack-free catalyst layers are feasible.