Oct. 14, 2002

Rensselaer Speeds MEA Production

Rensselaer has found the answer to producing membrane electrode assemblies (MEAs) — the vital core of fuel cells — quickly and accurately.

By automating the process of putting together gasket, electrode, and proton exchange membrane materials, the School of Engineering's Flexible Manufacturing Center (FMC) can create MEAs at least 10 times faster than a human can, and at levels of accuracy that are otherwise impossible to achieve.

Raymond Puffer, co-director of the FMC, and Stephen Derby '76, FMC co-director and associate professor in the department of mechanical, aerospace, and nuclear engineering, designed a 65- by 40-foot pilot assembly line for Celanese Ventures over the past two years. The ribbon-cutting for the line took place Sept. 2.

The project began in 1999, when Celanese approached chemistry professor Brian Benicewicz, who directs the New York State Center for Polymer Synthesis at Rensselaer, to develop a membrane material that can withstand high temperatures and be used in MEAs. Since some of the components of MEAs are very thin, fragile, and difficult to handle efficiently, Benicewicz suggested that the company enlist the help of the FMC to develop a fully automated system to assemble them.

The FMC, in turn, performed a conceptual design of an automated process, developed proof-of-principle laboratory prototypes, and wrote the system specifications. The FMC also served as the technical representative to the system contractor during the design and construction of the pilot line at a Celanese plant in Frankfurt, Germany. What's more, two grad students developed theses from the project (one has since taken a job at Celanese), and the FMC generated two patent applications based on the process. Celanese has even indicated that it may open a manufacturing center in the Capital Region in the not-so-distant future.

"This whole project is a model of how universities, industry, and individuals can work together-and benefit from it," said Puffer. "It's a win-win situation. From my perspective, it doesn't get any better than this."