Tutorial - Giosuè Giacoppo

TUTORIAL

Giosuè Giacoppo

Institute for Advanced Energy Technologies (CNR-ITAE), Italy

The increasing demand for clean energy technologies places hydrogen fuel cells at the center of future energy systems. Their integration into portable, stationary, maritime, and aerospace applications requires a robust engineering approach that goes beyond material innovation. Advancements in system design, performance optimization, and scalable manufacturability are essential to support broad-scale deployment.

This tutorial will focus on the fuel cell stack engineering methodology developed over more than twenty years of applied research and prototyping. It will walk through a comprehensive design process — from preliminary sizing based on target performance, flow field architecture, and bipolar plate layout, to executive design, virtual assembly, and detailed testing protocols. The presentation will include real case studies and validated workflows that translate concepts into operational stacks.

A special focus will be dedicated to recent investigations into lattice-based and TPMS-inspired flow field structures. Although still at a relatively early stage, these geometries appear promising for improving gas distribution, water management, and mechanical integration. Additionally, the tutorial will explore advancements in additive manufacturing, particularly Laser Powder Bed Fusion (LPBF), and how it enables the production of innovative bipolar plate configurations that support not only improved design flexibility, but also automation-oriented stack assembly processes.

This session will showcase results from national and European projects (e.g., ESA, PRR, FCH-JU) and offer a forward-looking perspective on fuel cell stack integration with a high Technology Readiness Level (TRL), suitable for new energy, transport, and aerospace applications.

Dr. Giosuè Giacoppo is a senior researcher at the Institute for Advanced Energy Technologies (ITAE) of the National Research Council of Italy (CNR). He holds a degree in Aerospace Engineering and has over two decades of experience in hydrogen-based energy systems, fuel cells, and electrochemical energy storage.
His scientific contributions include the design, simulation, and experimental validation of fuel cell stacks, from low-power portable systems to high-efficiency regenerative units for aerospace missions. Dr. Giacoppo coordinated the development of several prototypes, including a 1 kW stack for ESA and modular systems integrating PEMFCs with electrolyzers and vanadium redox flow batteries. His recent research has focused on the application of 3D printing techniques, such as metal LPBF, to develop lightweight and compact stack architectures aimed at improving both performance and manufacturability. Dr. Giacoppo has authored more than 45 peer-reviewed publications, served as principal investigator in national and EU-funded research projects, and collaborated with industrial partners for technology transfer. He currently leads R&D activities on next-generation bipolar plates and fuel cell integration in hybrid systems, contributing to the advancement of sustainable and scalable hydrogen technologies across multiple sectors.