Scalable 3D Printed Microlattices of Bimetallic Transition Metal/Metal Oxide Electrocatalysts
Anand P. Tiwari, J. Patterson, Md Saifur Rahman, William J. Scheideler
Abstract
Abstract The development of scalable and cost‐effective electrocatalysts is pivotal for a sustainable energy transition toward green hydrogen production. A scalable approach integrating surface morphology regulation with the transformation of 3D printed photopolymers into bimetallic transition metal/metal oxide ((Co/CoO x )(Ni/NiO x )) and carbon core‐shell microlattice electrodes for efficient electrocatalytic water splitting is presented. By precisely tuning the cobalt and nickel metal infusion, optimized conformally‐grown heterostructures have been achieved on carbon microlattices. These microlattices, featuring dual active sites and tunable electronic structures, significantly enhance reaction kinetics and improve electrocatalytic performance. Furthermore, 3D microlattices leverage mesoscale (100–200 µm) pores, which facilitate electrolyte accessibility, maximize utilization of active sites, and enable rapid bubble evolution. This structural advantage enhances catalytic efficiency and improves long‐term operational stability. The resultant core‐shell structures ((Co/CoO x ) 2 (Ni/NiO x )C) demonstrate exceptional activity for the hydrogen evolution reaction (HER), achieving low overpotential (130 mV at 10 mA cm 2 ) and Tafel slope (124 mV dec −1 ) in an alkaline medium. Moreover, these electrodes exhibit remarkable durability, maintaining stable performance over 100 h and outperforming state‐of‐the‐art Ni foam‐based electrodes. These findings highlight a scalable and effective strategy for designing advanced electrodes for hydrogen production, paving the way for their practical implementation in sustainable energy systems.