VSPARTICLE and Plug Power release breakthrough technology results

The collaborative project with Plug Power Inc. and the Center for Clean Hydrogen, directed by Professor Yushan Yan at the University of Delaware, achieved outstanding performance while using up to 90% less Iridium.

These results, detailed in the Electrochemical Society (ECS) Meeting in Chicago, surpass the DOE's 2026 targets for iridium utilisation and performance. This data confirms a viable pathway to green hydrogen production at US$1/kg, a cost that is competitive with hydrogen derived from steam methane reforming (SMR), which currently costs between US$1.50 - 2.50/kg according to the International Energy Agency (IEA).

Results from PLUG show VSPARTICLE’s technology demonstrated exceptional durability and efficiency, with less than 2.3 µV/h degradation over 8000 hours of operation – equivalent to a 10-year system lifetime – and have also shown an operating voltage of 1.74 V at 3.0 A/cm², enabling higher hydrogen output using the same amount of energy.

Following PLUG's presentation at ECS, VSPARTICLE also presented new data showing that spark ablation technology can reduce iridium usage by up to 90%, lowering loading from 1.0 mg/cm² to 0.1 mg/cm² while maintaining high performance.

“This data, combined with the scalability of our technology, turns this fundamental constraint into a scalable solution,” said Aaike van Vugt, CEO of VSPARTICLE. “Our dry deposition process isn't just an alternative to spray coating; it's a fundamental redesign of how we manufacture electrode that uses iridium with near-optimal efficiency. This is the missing link the industry has been searching for to scale PEM electrolysis to the multi-GW level without facing an iridium shortage.”

“The performance at 0.4 mg/cm² is exceptional,” stated Dr Thomas Valdez, Senior R&D Manager, Plug Power. “In our evaluation, VSPARTICLE's electrodes demonstrate the durability and high current density required for commercial systems. This level of iridium utilization is essential for Plug to achieve our cost-reduction and deployment goals.”

Transforming electrolyser economics with precision engineering

PEM electrolysers are favoured for their ability to respond dynamically to intermittent renewable energy. However, their reliance on iridium, one of the rarest platinum group metals (PGMs) with a global production of only 7 - 8 tpy, has been a major barrier to scale. Traditional catalyst coating methods are inefficient, often requiring 1 - 2 mg/cm² of iridium.

VSPARTICLE's technology addresses this by creating a highly uniform, nanoporous structure without PFAS-based ionomers or solvents. This not only maximizes the electrochemical surface area (ECSA) of the precious metal but also simplifies the manufacturing process and enables more efficient recycling.

The convergence of this technological leap with the ongoing decline in renewable electricity prices – which have fallen by 90% in the last decade for solar PV (source: IRENA) – creates a compelling economic case for green hydrogen, potentially achieving the DOE's ‘Hydrogen Shot’ goal years ahead of schedule.

Momentum towards industrial adoption and market impact

VSPARTICLE is scaling its in-house coating capacity to support pilot and early commercial projects with multiple top-tier PEM electrolyser manufacturers. Several partners have scheduled integration and commercial-scale testing programs to begin in 2026.

“This work directly addresses the most significant materials challenge in PEM electrolysis,” said Dr Yushan Yan, founding director of Center for Clean Hydrogen. “The combination of ultra-low loading and proven performance and durability de-risks the manufacturing of next-generation electrolysers. Widespread adoption of this technology could prevent an iridium supply crisis and fundamentally transform the economics of green hydrogen production. This catalyst layer deposition technology is also promising for AEM electrolysis.”

Read the article online at: https://www.globalhydrogenreview.com/hydrogen/15102025/vsparticle-and-plug-power-release-breakthrough-technology-results/