1-10 kW PEM Fuel Cell
Budget: $3,000 – $5,000 USD
My senior mechanical-engineering capstone revolves around a Proton Exchange Membrane fuel-cell system destined for stationary power generation in the 1–10 kW range. I need a complete, ready-to-present project package that covers every step from initial sizing through to functional validation.
Scope
• Analyse the power demand profile and translate it into stack requirements (cell count, active area, operating current density).
• Design the stack: flow-field plates, gasket layout, membrane-electrode assembly selection, compression hardware, and thermal management strategy.
• Specify the balance of plant—hydrogen supply, humidification, air delivery, cooling loop, sensors, and control logic—so the unit can run unattended on a bench.
• Produce manufacturing-ready CAD (SolidWorks or similar), exploded views, wiring diagrams, and a full bill of materials with vendor part numbers.
• Validate performance through simulation or benchtop testing: steady-state output between 1 kW and 10 kW, voltage stability, efficiency estimate, and safety checks (leak detection, purge routines).
• Package the findings in a professional report and slide deck that meets typical ABET senior-design standards.
Acceptance criteria
– Continuous DC output demonstrably within the 1–10 kW window.
– All drawings and calculations reproducible and appropriately referenced.
– BOM components commercially available or clearly noted as custom.
– Safety and maintenance considerations addressed.
I will handle final campus fabrication if shipping a physical prototype is impractical, so clear assembly instructions and test protocols are crucial. Familiarity with PEM stack design tools, MATLAB/Simulink, ANSYS or COMSOL for thermal/flow analysis, and standard lab instrumentation will be helpful.
Deliverables are flexible by milestone, but the end goal is a design I can confidently present, defend, and, if time allows, power up in the lab.
Scope
• Analyse the power demand profile and translate it into stack requirements (cell count, active area, operating current density).
• Design the stack: flow-field plates, gasket layout, membrane-electrode assembly selection, compression hardware, and thermal management strategy.
• Specify the balance of plant—hydrogen supply, humidification, air delivery, cooling loop, sensors, and control logic—so the unit can run unattended on a bench.
• Produce manufacturing-ready CAD (SolidWorks or similar), exploded views, wiring diagrams, and a full bill of materials with vendor part numbers.
• Validate performance through simulation or benchtop testing: steady-state output between 1 kW and 10 kW, voltage stability, efficiency estimate, and safety checks (leak detection, purge routines).
• Package the findings in a professional report and slide deck that meets typical ABET senior-design standards.
Acceptance criteria
– Continuous DC output demonstrably within the 1–10 kW window.
– All drawings and calculations reproducible and appropriately referenced.
– BOM components commercially available or clearly noted as custom.
– Safety and maintenance considerations addressed.
I will handle final campus fabrication if shipping a physical prototype is impractical, so clear assembly instructions and test protocols are crucial. Familiarity with PEM stack design tools, MATLAB/Simulink, ANSYS or COMSOL for thermal/flow analysis, and standard lab instrumentation will be helpful.
Deliverables are flexible by milestone, but the end goal is a design I can confidently present, defend, and, if time allows, power up in the lab.