­­Additive Manufacturing for Solid Oxide Cell Electrode Fabrication

Electrode microstructure plays a critical role in determining the electrochemical performance and durability of Solid Oxide Cells. Additive manufacturing can potentially offer a highly-defined electrode microstructure, as well as fast and reproducible electrode fabrication. Selective laser sintering (SLS) is an additive manufacturing technique in which the three-dimensional structures are created by bonding subsequent layers of powder using laser power.

Although selective laser sintering can be applied to a wide range of materials, including metals and ceramics, the scientific and technical aspects of the manufacturing parameters and their impact on microstructural evolution during the process are not well understood.  

In the present study this novel approach for electrode fabrication was evaluated by conducting a proof of concept study. A Ni-patterned fuel electrode was laser sintered on a YSZ substrate. The optimization process of laser parameters (laser sintering rate and laser power) and the electrochemical results of a full cell with laser sintered electrode are presented. The challenges and prospects of using selective laser sintering for SOC fabrication (for example, to create electrodes with unique 3D hierarchical porous structures) are discussed.