Key Technical Advantages:

• Flexible Porous Graphitic Matrix Technology: Conforms to varying cell designs without compromising strength. Ideally suited for roll-to-roll processes due to high tensile strength and the capability for reduced bending radius compared to traditional GDLs.
• Low Compressibility: The proprietary flexible graphitic matrix reduces cell creep and improves sealing. Its ultra-thin form factor and elastic compressibility minimize permanent compression set within the cell.
• Enhanced Performance with Superior Electrical Conductivity: Advanced graphitic matrix minimizes electrical resistance, boosting power output and efficiency. The unique microporous structure combined with a minimal hydrophobic coating ensures uniform gas flow and water management over a wide variety of operating conditions.
• Xtreme Durability in Harsh Environments: Corrosion-resistant graphitic matrix for long-term stability in both highly acidic and strong alkaline environments.

“FLEX-GDL™ simplifies manufacturing, delivers exceptional performance, and boasts robust durability in acidic and alkaline environments. The thin, flexible graphitic matrix reduces cell pitch, secures sealing with minimal creep, and reduces PTFE loading by 80% for enhanced efficiency and power output for fuel cell and electrolyzer applications,” said Jason Morgan, Director of R&D Engineering at AvCarb.

Market Impact:

• Enhanced Fuel Cell Efficiency: Improved reactant distribution and water management extend stack life. Its thin design significantly reduces cell pitch, enabling higher power density.

• Versatile Across Applications: Suitable for both automotive and stationary fuel cell systems, as well as electrolyzers used in hydrogen production and CO₂ utilization.

• Simplified Manufacturing: Flexible and strong for easier material handling, enabling reduced manufacturing and assembly costs.
• Lightweight & Scalable: Thin and flexible design supports high power density and commercial-scale production, available in widths up to 800 mm and rolls up to 1000 linear meters on 3-inch cores.

• Sustainability: Uses only non-toxic, aqueous-based chemistry for production of the graphitic matrix combined with an 80% reduction in PTFE loading compared to standard commercial GDLs.

Chris Holmes, President and CEO, added: “Consistent with AvCarb’s world-class capability to develop and deliver a continuous portfolio of Gas Diffusion Layer products, we are pleased to present to the market our latest development. FLEX-GDL has been developed by using our customer-centric product development mindset to address current and future demands of the Hydrogen Community.”

Whether powering zero-emission vehicles, supporting hydrogen production, or enabling CO₂ capture and utilization systems, AvCarb’s FLEX-GDL™ serves as a highly efficient, flexible “skin” within clean energy devices—enhancing performance, extending lifespan, and streamlining integration into production lines.

About AvCarb

AvCarb Material Solutions specializes in the development and production of advanced carbon materials. With a rich heritage dating back to the 1960s, we are a global leader in supplying innovative carbon-based solutions for industries including aerospace, energy, and chemical processing.
 

We design and manufacture high-performance engineered carbon materials such as fabrics, felts, and papers. Our products are known for exceptional quality, reliability, and performance —especially in high-growth electrochemical applications like fuel cells, electrolyzers, and advanced batteries.  Our deep technical expertise and commitment to innovation have earned us a reputation as a trusted provider of advanced carbon materials.

For more information, visit www.avcarb.com or contact Chris Robertson at chris.robertson@avcarb.com