KISSSEs instead of precious metals: Efficient laser solutions for electrolysis

Press Release / November 26, 2025

Over the next three years, the Fraunhofer Institute for Laser Technology ILT will be working with regional partners to develop new technologies to reduce the cost-intensive use of precious metals in proton exchange membrane electrolyzers. At Fraunhofer ILT's Hydrogen Lab, researchers are presenting the entire process chain – from simulation and testing to the manufacturing of components and systems for hydrogen technology.

© Fraunhofer ILT, Aachen, Germany.
The Hydrogen Lab covers 300 square meters and offers a wide range of laser technology test facilities for different dimensions and designs.

Global industrial demand for sustainably produced hydrogen is growing steadily. However, there is currently a shortage of electrolyzers capable of efficiently converting green electricity into hydrogen. Only with scalable, high-performance electrolysis technology can we utilize the full potential of renewable energies.

In October 2025, the research project “AI-supported welding and cutting of expanded metal meshes for the efficient production of electrolyzers” (KISSSEs) was launched. The aim of the joint project is to develop a technology that enables the more cost-effective production of electrolyzers. Instead of expensive, precious metal-coated grids, researchers at Fraunhofer ILT and two regional partners are striving to use laser-welded grids with the highest possible electrical conductivity.

Researchers at Fraunhofer ILT use artificial intelligence (AI) to identify optimal points for laser welding in complex grids, thereby improving conductivity. Precise laser welding of these points significantly reduces electrical contact resistance in titanium expanded metal grids and replaces expensive precious metal coatings. AI-supported laser cutting processes also optimize edges, further increasing the efficiency of the electrolyzers.

“Our AI models recognize the optimal welding points even with irregular expanded metal geometries, enabling reproducible contacts with lower resistance,” explains Zhiheng Ye, hydrogen expert at Fraunhofer ILT. “This lays the foundation for scalable and resource-efficient electrolyzer production.”

© Fraunhofer ILT, Aachen, Germany.
Zhiheng Ye, a doctoral student at Fraunhofer ILT, is working on new technologies that enable the manufacturing of electrolyzers without precious metals.

PEM electrolysis

The technology addressed in the project uses a proton exchange membrane (PEM) for electrolysis. In this process, the proton-conducting membrane electrochemically separates water into hydrogen and oxygen. It also serves as an electrolyte and gas barrier, enabling compact, dynamically controllable operation.

Proton exchange membrane systems are characterized by high power density, short response times, and excellent partial load capability, which makes them particularly suitable for use in combination with fluctuating renewable energy sources. PEM stacks from project partner iGas energy generate up to 260 standard cubic meters of hydrogen per hour. This corresponds to the volume of a large hot-air balloon. The stacks can be connected, ensuring that performance can be scaled up.

© iGas energy.
Green Electrolyzer: The small expansion stage of the iGas energy electrolysis plant serves to verify development results under real operating conditions on an industrial scale.

Regional value creation

In this project, Fraunhofer ILT is collaborating with iGas energy. The engineering and hydrogen company has developed the Green Electrolyzer, a PEM-based modular high-pressure electrolysis system, as well as a scalable PEM stack platform with the product name ELZA.

Another participant is dLS LichtSchneiderei, a Fraunhofer ILT spin-off specializing in precision manufacturing with a strong focus on laser and machining technology for bipolar plates in fuel cell and hydrogen technology.

Fraunhofer ILT is responsible for developing and optimizing laser-based welding and cutting processes as well as AI models for structure recognition at KISSSEs. iGas energy provides electrochemical system expertise, develops flow and cell models, and validates components in electrolysis operation. dLS LichtSchneiderei transfers the cutting parameters to industrial production, manufactures sample parts, and supports the transfer to production facilities.

“Hydrogen is an important component in a wide range of sectors in Germany and is to be produced ‘green’ in the future. PEM electrolysis is a key technology in this context,” emphasizes Karl-Heinz Lentz, Managing Director of iGas energy. “The establishment of this process and the associated value chain can make a decisive contribution to successful structural change in the Rhineland region.”

This close regional cooperation in the Rhineland region strengthens the technological basis for a competitive hydrogen economy and sets standards for innovative, locally anchored value creation networks in the energy sector.

KISSSEs is funded as part of the DigiRess program by the state of North Rhine-Westphalia and the Federal Ministry for the Environment, Climate Protection, Nature Conservation, and Nuclear Safety.

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Press Release from November 26, 2025