Micro-Additive Manufacturing Processes for Electrochemical CO2 Reduction

Student Name: Hunter Saylor Home Institution: Morgan State University NNCI Site: Cornell NanoScale Facility @ Cornell University REU Principal Investigator: Dr. Sadaf Sobhani REU Mentor: Giancarlo D’Orazio Abstract: This work investigates the application of micro-additive manufacturing in the development of gas diffusion electrodes (GDEs) for electrochemical CO2 reduction reactors. This technology relies on the principles of electrochemistry to convert CO2 into useful chemical products. A key focus of this work is the reactor design and fabrication, as these elements impact the overall efficiency and functionality of the system. The gas diffusion electrode is identified as a common failure point in such reactors. To enhance the performance and durability of the GDE, we utilize the Nanoscribe GT2 Two-Photon Lithography System to print a microporous layer atop a carbon paper electrode. This effort aims to prevent electrolyte flooding in our vapor-fed reactor. A copper catalyst will be deposited onto the microporous layer using the AJA Sputter System. Subsequent analysis of the GDE surface will be conducted using a Scanning Electron Microscope (SEM) to ensure structural integrity and optimal surface characteristics. To evaluate the performance of the CO2 reduction reactor, measurements of open-circuit potential, electrochemical impedance spectroscopy, and cyclic voltammetry will be scrutinized. The results will highlight common failure modes, such as catalyst delamination and electrolyte flooding. Additionally, a long-duration, steady-state test will be performed to measure changes in potential at a fixed current, providing insights into the long-term performance and lifespan of the GDE. Our findings will deliver quantitative insights into the optimization of gas diffusion electrode synthesis, advancing the efficiency of electrochemical CO2 reduction processes. This research underscores the potential of micro-additive manufacturing in addressing critical challenges in renewable energy and carbon capture technologies.