Fabrication & Assembly of PEM Water Electrolysis Hardware for Green H2 Production

MEA fabrication 

Assembling and working of the water electrolysis cell

@ ICIQ.ORG

Water electrolysis cell assembly (animation)

Directed the complete hands-on fabrication, mechanical assembly, and operational validation of a custom water electrolysis cell for green hydrogen production at the Institute of Chemical Research of Catalonia (ICIQ) in Tarragona, Spain. This project encompassed the practical engineering lifecycle of electrolyzer hardware preparation, bridging electrochemical theory with physical application.

The initiative involved the precise in-house fabrication of the Membrane Electrode Assembly (MEA), ensuring optimal catalyst integration for efficient electrochemical reactions. Following MEA preparation, the project required the meticulous step-by-step integration of all cell hardware components—including flow fields, gaskets, and current collectors—to guarantee strict gas-tightness and optimal electrical contact. The successfully assembled electrolyzer was then operationally validated for its efficiency in water splitting and steady-state hydrogen gas generation.

To support institutional knowledge and training, comprehensive visual documentation and instructional animations were developed, detailing the exact internal working mechanisms and the hardware assembly sequence of the cell.

Project Details:

• MEA Fabrication: Fabricated custom Membrane Electrode Assemblies (MEAs), ensuring optimal catalyst coating, structural integrity, and efficient proton exchange capabilities.

• Precision Cell Assembly: Executed the complex mechanical integration of the electrolyzer hardware, precisely aligning bipolar plates, seals, and the MEA to prevent gas crossover and ensure leak-proof operation.

• Operational Validation: Conducted rigorous functional testing of the fully assembled unit to validate water splitting efficiency and reliable H2 production under active operational parameters.

• Technical Visualization: Authored detailed visual media and instructional animations that document the step-by-step assembly process and the internal electromechanical working of the electrolysis cell.