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Researchers at Queen’s University Belfast have engineered a novel 3D-printed flow battery that holds promise for significantly advancing the pursuit of net zero emissions. Flow batteries play a crucial role in renewable energy systems by storing excess energy generated from wind and solar sources for later use during periods of low generation. Traditionally, these batteries rely on vanadium, a costly metal with limited global availability, which restricts their widespread adoption.
The team at QUB has innovated a flow battery design utilizing iron, a far more abundant and accessible element, aiming to enhance the scalability and consistency of renewable energy research worldwide. This new iron-based battery has already been distributed internationally to support standardization efforts, potentially accelerating the renewable energy transition by providing researchers with a reliable, affordable testing tool.
The creation of this battery stemmed from the personal research needs of Dr Hugh O’Connor, a postdoctoral scientist who initially sought a flow battery for his PhD investigations but was deterred by commercial prices ranging from £2,000 to £3,000. He began 3D-printing cells himself, refining the design through numerous iterations until achieving a functioning model. His breakthrough enabled him and his colleagues to pursue experiments at a fraction of the usual cost, fostering collaboration and shared development across the field.
Rather than commercializing his design, O’Connor, with encouragement from his supervisor, decided to release the blueprint freely to the international research community. The kit costs approximately £74 and comprises around ten components, including the printed housing, membrane, electrodes, and other parts. Accompanied by a detailed “Ikea-style” instruction manual, this open access approach ensures researchers can assemble the battery accurately and efficiently. Scientists such as Dr Josh Bailey at QUB are leading global efforts to use these standardized cells in multi-institutional studies, boosting reproducibility and helping to build a common foundation for accelerating flow battery technology toward industrial-scale deployment
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