The transition to a hydrogen-based economy is gaining momentum, driven by the need for clean energy solutions and government funding efforts. As part of this shift, R2R contract manufacturers play a crucial role in enabling efficient and scalable production processes. In this article, we explore the services offered by R2R manufacturers, with a focus on membrane casting and electrode coating.
Contact Verico Technology to discuss your R2R coating needs and challenges for product development, prototyping, scale-up and full-scale production of critical components for electrolyzers, fuel cells and other components of the hydrogen economy.
Verico offers coating services from lab and pilot scale to full production scale with two 65 inch wide production lines featuring three precision slot die coating stations and floatation ovens in a clean production environment.
Roll-to-roll manufacturing involves continuous processing of flexible materials on large rolls. It offers several advantages, including high throughput, cost efficiency, and scalability. R2R manufacturers specialize in producing components for various industries, including layers of electrolyzers and fuel cells.
Anion Exchange Membrane (AEM) Electrolysis
- R2R manufacturers provide membrane casting services for AEM electrolysis cells. These cells use a solid polymer electrolyte membrane to split water into hydrogen and hydroxide.
- The membrane casting process ensures uniform thickness and quality of the membrane, critical for efficient electrolysis.
- Ovens and drying strategy are also key considerations for efficient, high quality production. Membranes can be relatively thick layers cast from low percent solids solutions with difficult to dry solvents. Multi-zone ovens, configured to optimize drying through the various stages of the process, provide quality and efficiency.
Verico excels at producing uniform, defect-free membranes to exacting customer specifications. Slot die coating at Verico consistently produces single digit percentage thickness variation over a wide range of thicknesses, from sub-micron to hundreds of microns.
Verico engineering’s expertise in substrate properties and selection, solvent choices for coating and drying optimization, and deep knowledge of slot die coating, drying processes, and conveyance control combine to deliver outstanding results at pilot and production scales.
Catalyst-Coated Membranes (CCMs)
- CCMs are essential components in PEM electrolysis. They consist of a catalyst layer coated onto the membrane.
- CCMs are the next evolution for AEM electrolyzers, replacing catalyst coated substrates (CCS) in the membrane electrode assembly (MEA).
- R2R methods allow direct electrode coating on membrane films, enhancing production efficiency.
- Verico’s pilot and production scale R2R coaters offer efficiency in scaling these valuable constructions, from small scale prototypes using very little material to full scale production with minimal waste.
- Scalability: R2R processes can scale from prototype to large volumes, making them ideal for both early and mass production work.
- Cost Efficiency: Reduced material waste, lower labor costs, and streamlined production contribute to cost savings.
- Energy Efficiency: R2R minimizes energy consumption compared to batch processes.
- Lower CapEx: Contract manufacturing provides customers a zero capex solution to more quickly develop and scale R2R products. Only pay for the line time required instead of buying a dedicated, high capex machine that could take more than a year to purchase, install and learn to use.
- Faster Scale-up and Time to Market: Existing, flexible assets at a Contract Manufacturer not only eliminate capex but also provide a quicker path to develop and scale products. No waiting for a pilot coater to be designed, built, installed and started up. Contract manufacturers have these assets in place now.
R2R contract manufacturers are pivotal in advancing hydrogen technologies. By offering specialized services like membrane casting and electrode coating, they accelerate the adoption of clean energy solutions. As the hydrogen economy grows, collaboration between manufacturers, researchers, and industry stakeholders will drive innovation and affordability.
Verico Technology is excited to serve the growing hydrogen economy with roll-to-roll contract coating services. Advantages from Verico you can expect include:
Expertise: Verico’s expertise in coating processes and scale-up means you focus on your product, your chemistry, your application and customers. Instead of investing time and hiring experts to in-house roll-to-roll coating rely on Verico for this expertise. - Startup Friendly: Verico understands the needs of startups and works collaboratively with our customers to develop the best process for their products. Verico allows access to our equipment and all process data generated on customer projects. This unique, transparent approach speeds development.
- Lower CapEx: Verico’s significant capabilities and investment in pilot and advanced process features ensure our customers have access to a range of process options that required tens of millions of dollars in investment. All at a “pay as you go” service rate with no customer capital expenditure.
- Faster Scale-up and Time to Market: Verico is ready now with lab, pilot and production scale assets. Fast response and short lead times mean quicker development cycles and faster time to market.
Cleanliness – Our facility is clean and our processes have special attention to produce clean, defect-free products for our customjers.
Fast Track – Very quick response time and a wide range of assets to speed products through the development cycle and into production.
Flexibility – Verico’s team is flexible, creative and driven to solve challenges and deliver results for our customers.
Transparency – Verico opens its lines and processes to our customers, shares data and works collaboratively to speed development.
Product Development – Verico’s 30 plus year history of developing products for R2R scaleup allows our customers to leverage this deep experience and understanding of the materials and processes, from concept and design to high efficiency manufacturing.
Ready to Bring Your Product to Market?