10120879Scale-up of innovative electrolyser coating technology: SICTClosedCollaborative R&DInnovate UK**Oxford nanoSystems Ltd (OnS)** has developed nanoFLUX, a revolutionary nano-coating designed to optimize the efficiency of two-phase heat-exchangers. With a commitment to eco-friendly and cost-effective solutions, nanoFLUX introduces a highly porous coating that amplifies nucleation site density by over 10,000-fold, resulting in a remarkable increase in heat transfer efficiency by over 500%. This breakthrough technology, applicable to internal surfaces and micro-scale structures, surpasses conventional mechanical enhancements. Aligned with the UK's Net Zero commitment and the escalating demand for green hydrogen, OnS has directed its focus towards hydrogen generation via electrolysis. Our latest innovation targets the enhancement of alkaline water electrolysis (AWE), the most developed electrolysis method to date. By significantly improving the efficiency of the cathode, our technology promises to revolutionize hydrogen generation. Notably, the characteristics required to optimize electrolysers resemble those seen in enhancing heat exchangers through our coating technology. Utilizing an augmented nanoFLUX coating, we aim to amplify the surface area of the cathode and diminish overpotential through enhanced bubble nucleation and release. This approach dramatically increases catalytic sites and overall efficiency, presenting a unique and cost-effective solution unparalleled in the market. Our ground-breaking results have earned us immense interest from all global leaders in the hydrogen industry. We are under NDA 19 manufacturers due to the outstanding performance of our smaller-scale samples. However, achieving uniformity in our coatings for large industrial-size membranes and meshes poses a critical challenge. While we have developed chemical baths for large samples, ensuring coating quality remains a hurdle. Although shielding has proven effective for small samples, scaling up for very large samples presents a distinct challenge. With no off-the-shelf solution available, and limited resources for 3D simulations, an experimental approach is costly and unfeasible. In light of these challenges, we seek assistance from the STFC Hartree National Centre for Digital Innovation, led by Ubaid Qadri and his expertise in 3D simulations. We hope that this collaboration will help us understand the field distribution and fluid agitation within the tank, ultimately developing uniformly coated surfaces. Our success in coating small test samples from industry giants underscores the urgency and potential impact of this project. Assistance from the STFC Hartree National Centre for Digital Innovation will be instrumental in advancing our electrolyser coating product to the final stages of commercialization, driving us closer to our vision of a greener and more sustainable future.