Rapid prototyping of Solid Oxide Fuel Cells

Rapid prototyping (RP) technologies can automatically manufacture near-net shape parts with complicated geometry from Computer-Aided Design (CAD) data. The three dimensional part is built up by powder consolidation in layers ("additive" or "generative" process). For this reason, these techniques are often referred to as solid freeform fabrication or layered manufacturing. In general, a five-step approach of the product development is commonly applied: creating a CAD model, converting the CAD model into STL format, slicing the STL file into cross-sectional layers, fabrication of the product, and finally surface finishing of the product. RP techniques have many benefits over traditional methods for model generation, tools and even construction of production-quality parts. For instance, in contrast to "subtractive" processes (e.g., drilling, milling, grinding) the "additive"-RP methods allow fabrication of products with complex geometries like undercuts, internal cavities or overhangs that cannot be manufactured by other approaches. Additive RP methods also offer the possibility to generate parts with an orientated internal pore structure. RP techniques can significantly shorten fabrication times of Solid Oxide Fuel Cells (SOFC) with small operational expenditure and reduced product costs when applied properly. Technologies such as Selective Laser Sintering (SLS), Laminated Object Manufacturing (LOM) and 3D Printing (3DP) may be used for the fabrication of fuel cell prototypes particularly for planar configuration.