As the world accelerates towards a net-zero future, hydrogen has emerged as a cornerstone of clean energy strategies. Powering this green revolution lies a transformative technology: electroforming. Once primarily used in precision manufacturing for electronics, electroforming plays a pivotal role in scaling and optimising hydrogen production systems.
electroforming and electrolysis
Building components atom by atom, electroforming allows for exceptional control over thickness, geometry, and surface finish to create precise metal parts.
This precision makes electroforming – in the hands of our skilled engineers - ideal for creating complex, high-performance components used in electrolysers—the devices that split water into hydrogen and oxygen using electricity.
With our patented Ni-E³ process, we are able to produce durable and sustainable electrodes for electrolysis. This improves production yield as well as financial efficiency due to zero waste and 100% recyclable products.
The electrodes produced by the Ni-E³ process can achieve up 14% greater surface area than alternative methods. In addition, several coatings can be applied that can further result in a surface enlargement of up to 20,000 times resulting in yields that are unprecedented in today’s world. The Ni-E³ process is extremely sustainable due to zero waste making it a very cost-effective and future-proof technology in producing electrodes. Our skilled engineers co-develop ground-breaking electrode solutions where aspects of the product can be customised to fit the customers’ specific needs such as thickness of the product and surface structure.
why electroforming matters in hydrogen production
Hydrogen production, particularly green hydrogen via water electrolysis, demands components that are:
- Highly conductive
- Corrosion-resistant
- Geometrically complex
- Cost-effective at scale
Our electroforming technology meets all these criteria. Here's how:
Enhanced Electrolyser Efficiency
Electroformed components, such as bipolar plates and porous transport layers, offer ultra-smooth surfaces and precise channel geometries. This improves gas flow, reduces electrical resistance, and enhances overall electrolyser efficiency.
Scalability and Repeatability
The process is highly repeatable and scalable, making it ideal for mass production of standardised electrolyser components—critical for meeting the growing global demand for hydrogen.
Design Freedom
With electroforming, manufacturers can create intricate microstructures that are difficult or impossible to achieve with traditional methods. This opens the door to next-generation electrolyser designs with improved performance and durability.
real-world impact
Several companies are already leveraging electroforming to push the boundaries of hydrogen technology. For example:
- Precision electroformed flow fields are being used in PEM (Proton Exchange Membrane) electrolysers to improve gas distribution and reduce pressure drops.
- Electroformed nickel components are enhancing the durability of alkaline electrolysers in harsh environments.
the road ahead
As hydrogen infrastructure expands—from fueling stations to industrial-scale production—electroforming continues to be a key enabler of cost-effective, high-performance systems. Its ability to deliver precision, efficiency, and scalability makes it a hero in the transition to clean energy.
conclusion
Electroforming’s impact on the hydrogen economy is profound. By enabling the production of advanced components with unmatched precision, it is helping to make green hydrogen more accessible, affordable, and efficient.
Veco’s NiE3 solution is particularly attractive for parties seeking increased cell performance, reduction of green hydrogen production costs and rapid scalability of electrolysers. This positioning makes Veco's electroforming technology not only unique, but also very strategically valuable in the hydrogen market.