Autostack – Optimised and automated Norwegian production of low cost, high efficiency PEM electrolysers

The Autostack project aimed to reduce costs associated with green hydrogen production by enabling economies of scale through mass manufacturing of PEM electrolyser stacks. The existing state-of-the-art production methods were at start of project low-volume and relied heavily on manual processes, making them inefficient and costly. The primary objective of the project was to decrease the capital expenditure (CAPEX) of PEM electrolysers for green hydrogen production. This was to be achieved through high-volume automated manufacturing of electrolyser stacks. Mass production design is essential not only to make zero-emission green hydrogen cost-competitive with the traditionally CO2-intensive gray hydrogen production methods but also to meet the anticipated future demand for electrolysers. A significant research challenge addressed by the project was how to achieve mass production of PEM electrolyser stacks in a cost-efficient manner while maintaining the required quality. The automated assembly process is highly complex, involving multiple individual steps per cell. Each cell are composed of ultrathin components that required precise positioning and alignment. Further complicating the process, these components possesses challenging characteristics, such as being brittle or floppy. The project developed methods and processes for assembling the required quality at high speeds and in a cost-efficient manner. This included identifying optimal assembly techniques, and design of a lean supply chain minimizing working capital and lead time. Additionally, the project worked on implementing circular economy models for stack production and reuse to enhance sustainability. The results of this project were a major factor in securing a 26.2 million EUR grant from the EU Innovation Fund in October 2024. The work completed through the Autostack project provided a strong foundation in the application with a reliable and trustworthy mass manufacturing solution for PEM electrolyser stacks.

The Autostack project focused on developing a comprehensive industrialisation concept for the high-volume, zero-defect production of PEM electrolyser stacks. The project’s innovation lay in its integration of advanced design principles, scalable production systems, and intelligent logistics to enhance efficiency and sustainability. The concept comprised the following key elements: Advanced Design for Manufacture and (Dis)assembly (DFMA) – The project introduced innovative design features to enable the pre-assembly of components into cell packs, streamlining the final assembly process and increasing stacking speed. Additionally, the design facilitated ease of disassembly, re-use, and recycling of high-value stack components, thereby reducing dependency on critical raw materials. Scalable and Flexible Production Systems – Multiple production systems were designed and simulated, accompanied by feasibility studies to evaluate various quality inspection and assembly methods. These efforts focused on achieving high-precision assembly of electrolyser stacks while ensuring zero-defect production. Intelligent Logistics and Integrated Supply Chain – The project implemented robust quality control systems and functional stack testing to meet zero-defect objectives. Additionally, efficient material handling strategies were simulated to support continuous and optimised workflows across the entire supply chain. The Autostack project played a crucial role in shaping the design of the planned 1.5 GW PEM electrolyser factory at Høvik and contributed significantly to securing funding from the EU Innovation Fund in 2024 for the establishment of the facility

This project aims at reducing the CAPEX of PEM electrolysers for green hydrogen production by enabling high-volume automated manufacturing of electrolyser stacks. Mass production is necessary to meet the future demand for electrolysers. The Autostack project will build upon the results from the ongoing NFR project Hystack and develop innovative solutions for high volume, zero-defect production of advanced PEM electrolysers. The main goal of the project is to design and validate an automated assembly process for PEM electrolyser stacks enabling up to 500MW/year of stack production The most prominent research challenge that this project will solve is how mass production of PEM electrolyser stacks can be performed in a cost-efficient manner with the required quality. The automated assembly process is complex, with several individual steps per cell and very high requirements on positioning and alignment of these components. It is therefore necessary to investigate possibilities for using pre-assembled cell modules or sub-assemblies to increase the final stack assembly efficiency and quality. This R&D challenge can be divided into three categories • What is the most cost-effective production line for mass production of PEM electrolyser stacks? • How can quality control be included in an automated production line for PEM electrolysers? • How should production planning be conducted to minimize delivery time for customers, while simultaneously mitigate holding cost for Hystar?