KnitMesh Featured in DLR Study on Hydrogen Efficiency Layers

DLR research highlights KnitMesh’s porous transport layers as a game-changer for green hydrogen electrolysis efficiency.

KnitMesh Technologies, a global leader in engineered knitted wire mesh solutions, has been recognized by the German Aerospace Center (DLR) in its recent white paper on porous transport layers (PTLs) for hydrogen production. The DLR study reveals that PTLs made from knitted wire mesh can significantly enhance system efficiency, durability, and cost-effectiveness in water electrolysis applications.

In a new technical paper published by the DLR Institute of Engineering Thermodynamics, researchers explored how porous transport layer design affects performance in green hydrogen electrolysis systems. Among the tested materials, the KnitMesh Technologies knitted wire mesh PTL demonstrated superior results in efficiency, current density, and energy consumption.

Key Findings from DLR Study

In single-cell tests (4 cm², 1 M KOH, 60 °C), the DLR team found that the cell equipped with KnitMesh’s knitted wire mesh PTL:

• Increased current density by 33% compared to a standard setup.
• Reduced cell voltage by 74 mV at 2 A cm⁻² — indicating lower energy usage.
• Ensured even compression across the active area.
• Enhanced gas removal for improved bubble detachment.
• Maintained excellent electrical and thermal conductivity while offering optimal permeability.

Why Knitted Wire Mesh Outperforms Traditional PTLs

The flexibility of knitted wire mesh allows it to behave like a precision spring, evenly distributing compression and maintaining stable contact with catalyst layers. This unique structure supports two-phase flow, promotes gas removal, and ensures steady electrolyte access to reaction sites — critical for efficient and reliable hydrogen production.

Furthermore, the mesh design can be tailored for porosity, thickness, and filament diameter, enabling fine-tuning of conductivity and mechanical resilience. This adaptability makes knitted wire mesh an ideal solution for next-generation hydrogen electrolysers.

“This study from DLR reinforces our findings that knitted wire mesh offers a powerful combination of flexibility, conductivity, and permeability,” said Craig Jones, Engineering Manager at KnitMesh Technologies. “As the hydrogen sector grows, advanced materials like ours will play a key role in improving efficiency and reducing costs.”

About KnitMesh Technologies

Established in 1957, KnitMesh Technologies designs and manufactures bespoke knitted wire mesh components used in hydrogen systems, gas diffusion layers, and porous transport layers. Headquartered in the United Kingdom with a manufacturing base in New Delhi, India, the company partners with leading hydrogen innovators to develop performance-driven, sustainable engineering solutions.

Learn more: https://knitmeshtechnologies.com/