Advanced AEM stack design focuses on optimizing the core component of AEM electrolyzers—the stack, which consists of alternating anion exchange membranes and electrode assemblies—to enhance efficiency, durability, and power density. Hyto Energy’s advanced AEM stack design is a key driver of the performance of their AEM electrolyzers, enabling them to compete with established electrolysis technologies. A primary aspect of advanced AEM stack design is minimizing internal resistance. Hyto achieves this by optimizing the interface between the membrane and electrodes, ensuring tight contact to reduce ion transport losses. This involves precision manufacturing of electrodes with uniform catalyst layers and porous structures that facilitate efficient gas diffusion and water distribution, critical for maintaining consistent reaction rates across the stack. Stack durability is another focus, with advanced designs incorporating materials and configurations that withstand the harsh alkaline environment and repeated cycling. Hyto uses corrosion-resistant bipolar plates and robust sealing technologies to prevent electrolyte leakage and gas mixing, extending the stack’s operational life. This is particularly important for industrial applications requiring long-term, continuous operation. Power density is also enhanced in advanced AEM stack design, allowing for higher hydrogen production per unit volume. By reducing the thickness of components (while maintaining structural integrity) and optimizing flow fields for water and gas management, Hyto’s stacks generate more hydrogen in a smaller footprint, making them suitable for both compact distributed systems and large-scale industrial units. Additionally, advanced stack designs incorporate thermal management features to dissipate heat evenly, preventing hotspots that can degrade membranes and catalysts. This ensures consistent performance even under varying load conditions, such as those encountered when integrated with renewable energy sources. Hyto’s advanced AEM stack design represents a balance of efficiency, durability, and compactness, driving the commercial viability of AEM electrolyzers. For detailed stack specifications, contacting Hyto Energy is recommended.