Researchers at the University of New South Wales (UNSW) say they have redesigned hydrogen fuel cells to address a long-standing performance issue caused by water becoming trapped inside the cell, a problem that can limit efficiency and complicate commercial deployment in heavy transport and aviation.
The multidisciplinary team, led by Dr Quentin Meyer and Professor Chuan Zhao from UNSW’s School of Chemistry, reported the work in the journal Applied Catalysis B: Environment and Energy. The researchers say the design aims to improve how excess water and gas leave the fuel cell, reducing the need for additional water-management systems that can add cost, complexity and weight.
Hydrogen fuel cells generate electricity through a chemical reaction, producing water as a byproduct. While that makes them attractive for low-emissions energy use, particularly where batteries face weight and range constraints, water management inside the cell remains a barrier for reliable, high-performance operation. According to the researchers, water can accumulate and block oxygen flow, lowering output.
UNSW’s approach uses micro-scale engineering to introduce small channels in the cell’s internal structure. The team said the channels are about 100 micrometres wide and separated by micro-ribs of the same size, creating what it describes as “lateral bypasses” to help water escape before it builds up.
“Our design can make hydrogen fuel cells much more efficient with only minor structural changes,” Dr Meyer said in the release. He also said the redesigned cell achieved “75% more power than traditional designs.”
Professor Peyman Mostaghimi and Dr Ying Da Wang, also from UNSW, said the work combined advanced imaging, fluid flow simulations and precision micro-engineering to rethink fuel cell structures.
The researchers said the design could also reduce reliance on costly metals such as platinum and support lighter systems, which are key considerations for aviation. The team said it is targeting nearer-term applications such as low-altitude aircraft, and that the lateral bypass technology has been patented by Dr Meyer and Professor Zhao as they work to scale the approach.
