The longevity of electrocatalysts is a crucial factor for the market ramp-up of hydrogen technology. Conventional platinum-based catalysts exhibit a significant voltage drop over their operational lifetime, particularly at low loadings—a problem that has so far limited the economic viability of fuel cells and electrolysers.

New Catalyst Concept: Embedded Yet Active

The research team at the DLR Institute of Technical Thermodynamics in Stuttgart is addressing this challenge with a novel electrode called Pt-e-Cn (Platinum embedded nanoscale carbon network). In this design, platinum particles are embedded in a porous, cross-linked nanocarbon framework. This structure provides physical protection against degradation processes—such as the Ostwald ripening process or particle agglomeration—while remaining fully accessible for electrochemical reactions.

The chosen manufacturing process is crucial for future scalability: The structure is produced via a flame-based rapid process that is cost-effective and suitable for industrial-scale production. This distinguishes the approach from many laboratory developments that fail due to complex synthesis routes that are difficult to scale up.

Result of European Research Collaboration

This development is a result of the EU project SUSTAINCELL, which aims to establish a durable and sustainable supply chain for fuel cell and electrolyzer components within the EU. As part of the consortium, DLR collaborated closely with the École polytechnique fédérale de Lausanne (EPFL) in Switzerland and the Commissariat à l’énergie atomique et aux énergies alternatives (CEA) in France.

Scientific Publication

The study on the Pt-e-Cn structure was published in June 2026 in the journal *Carbon Energy*. The manuscript is available via the following DOI: https://doi.org/10.1002/cey2.70300

This publication lays the scientific foundation for the production of long-lasting catalyst structures. The research team expects that the flame-based process will accelerate upscaling and thus significantly advance the market entry of long-lasting hydrogen technologies.

Video