The Open Fuel Cell (OFC) wouldn’t be what it is today without the SAFEREF project, which ran from 2020 to 2023. SAFEREF, short for “Development of Reference Electrodes for Safe Operation of PEM Fuel Cells”, was a collaborative effort to improve the safety and efficiency of hydrogen fuel cell systems. It brought together the Zentrum für BrennstoffzellenTechnik (ZBT) in Duisburg and Hahn-Schickard, a research institute specializing in microtechnologies. Their mission? To tackle one of the trickiest challenges in hydrogen fuel cell technology: making it safer, more reliable, and easier to integrate into real-world applications.
What Was SAFEREF All About?
Fuel cells are a promising clean energy technology, but operating them safely and efficiently requires pinpoint accuracy in monitoring and control. SAFEREF aimed to address this by developing a dynamic hydrogen reference electrode (DHE) that could detect conditions leading to local hydrogen shortages in the cell—conditions that can damage the system if not corrected.
To complement this, the team also developed an innovative sensor unit, the Anode Sensor Unit (ASE), to monitor gas flow, temperature, and hydrogen concentration in the system. Together, these technologies would enable a more precise, automated way to keep fuel cells running safely and efficiently, extending their lifespan and making them more cost-effective.
A Hands-On Approach to Research
Creating and testing these systems required an innovative twist. SAFEREF needed a testbed that was accessible and adaptable—not the complex and expensive setups typically used in research. This led to the development of a “low-cost” fuel cell, made using 3D printing and CNC machining. The result was a simple yet functional test cell that could mimic the behavior of full-scale systems while being easy to produce.
This approach not only supported SAFEREF’s research but also laid the groundwork for the Open Fuel Cell. The test cells were robust, affordable, and versatile, which made them perfect for exploring new ideas and applications.
The Collaborative Spirit
SAFEREF was a true team effort. ZBT brought its expertise in hydrogen technologies, while Hahn-Schickard contributed its advanced sensing and microfabrication know-how. Together, they tackled everything from designing thin-film electrodes to integrating sensors into real fuel cell systems. The project also worked closely with industrial partners and educators, ensuring the results could be applied to both advanced energy systems and training the next generation of engineers and scientists.
For more details, you can download the full project report (in German) here: SAFEREF Project Report.