Novel printed fuel cell with integrated gas channels

A method for printing a fuel cell having integrated gas channels, the method comprising:

• printing a sacrificial material periodically to a surface of a metal anode substrate, wherein at least some portions of the metal anode substrate have no sacrificial material printed thereon;
• printing or laminating a first gas diffusion layer to conform to a surface of the sacrificial material;
• infusing or coating a first catalyst material to the first gas diffusion layer;
• printing an electrolyte material onto the infused first applied catalyst material;
• infusing or coating a second catalyst material to the electrolyte material;
• printing or laminating a second gas diffusion layer onto the electrolyte material with the second catalyst material;
• applying a cathode to the second gas diffusion layer;
• and
• removing the sacrificial material, to form integrated gas channels of a monolithically formed fuel cell.

A printed fuel cell having integrated gas channels comprising:

• an anode layer;
• a first gas diffusion layer periodically fixed to the anode layer, wherein the periodically fixed first gas diffusion layer defines hydrogen flow field channels;
• a first catalyst material coated or infused to the first gas diffusion layer;
• an electrolyte membrane covering portions of the anode layer and the first gas diffusion layer with the first catalyst material;
• a second catalyst material coated or infused to the electrolyte membrane;
• a second gas diffusion layer in operative association with the electrolyte membrane and the second catalyst material, on a surface of the electrolyte membrane different from a surface of the electrolyte membrane which is in contact with the first gas diffusion layer;
• and
• a perforated cathode in contact with the second gas diffusion layer.