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Additive Manufacturing for Functional Energy Devices

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Thesis embargoed until 29th September 2027(6.32 MB)

Date

2024

Authors

Kumar, Vikash

Supervisor

Singamneni, Sarat
Huang, Loulin

Item type

Thesis

Degree name

Doctor of Philosophy

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Publisher

Auckland University of Technology

Abstract

With the era of fossil fuels gradually fading and the environmental concerns ever-increasing, other energy sources such as fuel cells, batteries, and H2 production take centre stage. While progress is imminent in different directions, manufacturing limitations have often been the source of retardation. Additive manufacturing technologies are upcoming with the unique attributes to achieve unlimited complexities in the designed forms and the choice of ever-increasing material options, which can offer potential solutions. Research progress has been evident in recent years, attempting the use of different additive technologies to improve the performance attributes of many energy devices. Still, there are wider opportunities that have not yet been explored. The present investigation attempts to fill this gap, exploring the roles additive manufacturing technologies can play in selected energy systems. Three specific energy systems, Microfluidic Fuel Cells (MFFCs), Microbial Electrolysis cells (MECs) for hydrogen production, and Dye-Sensitized Solar cells (DSSCs), are considered for the current research. MFFCs based on different rasterization paths such as planar, corrugated and corrugated-planar honeycomb structures, and functional architectures such as interdigitated and multi-channel honeycomb structures have been developed and employed as fluid flow channels with controlled internal structures made possible by the additive consolidation of materials. Inter-digitated and spiral forms of electrode assemblies fabricated by selective laser melting with AlSiMg10 and stainless steel 316L have been evaluated for the hydrogen production from wastewater by the means of the microbial electrolysis cells. The effects of polypyrrole coatings on the printed stainless steel 316L electrodes have also been ascertained. Fractal patterned polymer substrates fabricated by fused deposition modelling of transparent filaments have been evaluated for use as electrodes in dye-sensitised solar cells. Microfluidic fuel cells based on the printed flow channels with controlled fluid flow pathways achieved by the additive fabrication methods have been proven to perform better than the paper-based counter parts currently reported in the literature, while the scaled-up honeycomb structures scored the best in terms of the maximum current and power densities achieved. The spiral electrode configurations with polypyrrole coated stainless steel 316L anode manufactured by selective laser melting have shown promising results in microbial electrolysis cells. Apart from the high flexibilities, the fractal structured polymer substrate-based electrodes also proved to be best performing compared to the other cases studied. Evidently, the experimental and numerical results prove the hypotheses stated to be valid and established additive manufacturing as a promising new direction to consider for enhancing the performance of the three energy devices evaluated.

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http://hdl.handle.net/10292/18077

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