Advances in Materials and Manufacturing for Scalable and Decentralized Green Hydrogen Production Systems

The expansion of green hydrogen requires technologies that are both manufacturable at a GW-to-TW power scale and adaptable for decentralized, renewable-driven energy systems. Recent advances in proton exchange membrane, alkaline, and solid oxide electrolysis reveal persistent bottlenecks in catalysts, membranes, porous transport layers, bipolar plates, sealing, and high-temperature ceramics. Emerging fabrication strategies, including roll-to-roll coating, spatial atomic layer deposition, digital-twin-based quality assurance, automated stack assembly, and circular material recovery, enable high-yield, low-variance production compatible with multi-GW power plants. At the same time, these developments support…