PEM Electrolyzer Coating Systems
Ultrasonic Coating Technologies for Electrolyzers
Sono-Tek ultrasonic spray platforms deliver high-quality catalyst coatings and thin film layers for advanced electrolyzer manufacturing. Our ultrasonic coating systems apply controlled coating solutions onto electrolyzer substrates including electrodes, proton exchange membranes, gas diffusion layers (GDL), and other MEA-related components. With precise nozzle control and programmable flow rate, ultrasonic spray enables repeatable catalyst deposition using a catalyst deposition machine designed for material science-driven electrochemical performance in both bench top development and high-volume PEM electrolyzer production.
PEM Electrolyzer and Proton Exchange Membrane Coatings
In a PEM Electrolyzer, overall electrochemical efficiency depends on uniform catalyst layers and stable interfaces within the membrane electrode assembly (MEA). Sono-Tek Membrane Coating System technology supports multiple process routes, including catalyst-coated membrane (CCM) approaches, by depositing Platinum Catalyst and alloy-based catalyst layers directly onto Proton Exchange Membrane substrates or onto electrode/GDL structures before lamination.
Ultrasonic spray produces a soft, low-velocity mist that builds thin film coatings uniformly, preserving membrane integrity while maximizing active surface area. This enables consistent PEM performance, controlled gas transport, and reliable long-term operation.
Catalyst Deposition Machine and Catalyst Layer Control
Sono-Tek systems serve as a catalyst deposition machine for PEM electrolyzers where precision loading and morphology matter. Ultrasonic spray supports:
- Highly uniform catalyst deposition with controllable film thickness
- Stable slurry and nanoparticle coating solutions at low or high flow rate
- Consistent catalyst layer builds for anode and cathode electrodes
- Excellent surface area utilization for Platinum Catalyst and advanced alloys
Because ultrasonic energy gently de-agglomerates catalyst particles during atomization, coatings remain well-dispersed, improving electrolysis efficiency while reducing precious-metal waste.
Thin Film Coatings on Diverse Electrolyzer Substrates
Electrolyzer architectures combine multiple substrate types. Ultrasonic spray can coat thin film layers on:
- Proton Exchange Membrane substrates for CCM and MEA builds
- Anode and cathode electrodes, including porous transport layers and GDL structures
- Metallic or carbon-based substrates requiring uniform catalyst deposition
- Wide-area roll or sheet substrates where consistent film thickness and surface area are critical for electrochemical performance
Non-contact ultrasonic coating preserves delicate surfaces and supports uniform coverage over complex geometries.
Process Flexibility for Material Science and R&D
Electrolyzer development cycles often involve rapid formulation changes in electrolyte, catalyst slurry, or nanoparticle inks. ExactaCoat™ bench top systems allow researchers to tune:
- Flow rate and deposition rates
- Nozzle frequency and droplet size for morphology control
- Film thickness from nanolayers to multi-micron catalyst layers
- Pass overlap and drying profiles to optimize electrochemical interfaces
This flexibility supports faster iteration in material science programs and smoother scale-up to production.
Scalable Membrane Coating System for High-Volume Manufacturing
Sono-Tek PEM electrolyzer coating platforms scale from lab to factory using the same ultrasonic spray core. Multi-nozzle arrays and roll-to-roll or inline conveyor configurations support high-throughput coating of large-area membranes, electrodes, and GDL substrates. Manufacturers choose ultrasonic spray because it enables:
- Repeatable thin film and catalyst layer deposition
- Uniform coatings over wide substrates with minimal overspray
- Efficient use of Platinum Catalyst and advanced alloy chemistries
- User-friendly operation for validated, high-volume electrolysis manufacturing
Talk to an Applications Engineer – Tell us about your electrolyzer application. Sono-Tek will recommend the right ultrasonic nozzle, coating solutions delivery method, catalyst deposition strategy, and Membrane Coating System configuration to meet your targets for PEM Electrolyzer performance, film thickness, surface area, and production throughput.