The IMTEC main objective is to enable additive and advanced near-net-shape manufacturing processes to achieve increased production capacity for novel products in the net-zero industry. We will develop three cost-effective prod-uct lines for two different reversible Solid Oxide Cells (rSOC) demonstrators. Data mining, digital twins, and topol-ogy optimization will enable the upscaling of component manufacturing into pilot scale.

IMTEC will differentiate itself from the complementary topic HORIZON-CL4-INDUSTRY-2025-01-TWIN-TRANSITION-34 in that it will not integrate solid oxide cells into energy-intensive industries but will focus on processes for their manufacture.

Ceramic Solid Oxide Cells (SOC) are a promising clean solution for energy generation and conversion, that has advanced significantly in recent years. Utilizing ceramic materials for electrolytes and electrodes allows for high operating efficiency at temperatures between 600-1000 °C, effectively converting of fuels like hydrogen and natural gas into electrical energy and vice versa. When operated as fuel cells (SOFC), they achieve efficiencies up to 90%, three times more than combustion engines (vs. 40-70% for low temperature technologies). They can use different fuels, a decisive advantage regarding the use of energy-dense fuels. Conversely, SOFC can also function as solid oxide electrolyzer cells (SOEC) to split water into hydrogen and oxygen. Reversible solid oxide cells (rSOC) can be operated in both ways and contribute to energy grid stability by storing excess renewable energy. However, the mass deployment of SOC is hindered by outdated manufacturing processes from the 1980s, resulting in several challenges:

• Limited 3D design flexibility, hindering performance improvements.
• High production costs due to inefficient methods.
• Complex recycling processes for rare earth elements, raising concerns about scalability and sustainability.
• Multiple manufacturing steps and the need for dedicated production plants.
• High environmental impact of the product due to energy-hungry thermal treatments.

IMTEC aims to tackle these challenges by advancing two shaping complementary technology platforms: (i) multi-material Ceramic Injection Molding (CIM) with innovative variants for scalable 3D rSOC components, and (ii) multi-material additive processes for flexible, complex architectures and lower-volume production. These approaches will be combined with fast, energy-efficient thermal processes for co-debinding and co-sintering. AI based design and process modelling will support the development. Two rSOC-systems will demonstrate and validate the innovations:

• Demonstrator 1: For SOEC and co-SOEC stationary operations.
• Demonstrator 2: For SOFC operations specifically designed for mobility applications.

The scope of IMTEC is to advance SOC production technology by unlocking new product features and performance gains through advanced design concepts, enabling circular design principles, minimizing the use of raw materials, and reducing the dependence on critical raw materials.