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3D-printed fuel cells could reshape sustainable aerospace applications

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3D-printed fuel cells could reshape sustainable aerospace applications


Planar vs 3D SOC. Credit: Nature Energy (2025). DOI: 10.1038/s41560-025-01811-y

A team of researchers at DTU may have cracked one of the toughest nuts in sustainable energy: how to make fuel cells light and powerful enough for aerospace applications.

An interdisciplinary collaboration between DTU Energy and DTU Construct has developed a radical redesign of the so-called solid oxide cells (or SOCs), using 3D printing and gyroid geometry. This intricate structure is mathematically optimized to improve surface area in a given volume and is employed both by engineers for heat exchangers and by nature in structures such as butterfly wings.

Gyroidal architecture is structurally robust, has a large , and is lightweight. For the first time, DTU scientists have shown how to use the gyroid to make electrochemical conversion devices such as SOCs.

To power a commercial airplane today, you need . If you retrofit a regular jet, replacing its 70 tons of fuel with Li-ion batteries of similar capacity, its weight would be 3,500 tons. And so it wouldn’t take off.

The same has been true for fuel cells, mostly confined to flat, heavy stacks that rely on for sealing and connectivity. So, those are heavy, too. Metal components make up more than 75% of a fuel cell system’s weight, severely limiting their mobility and consequently, their usefulness in, for example, aerospace applications.

Sustainable flight?

In a new paper published in Nature Energy, DTU scientists may have flipped the script. Professor Vincenzo Esposito from DTU Energy, Senior Researcher Venkata Karthik Nadimpalli from DTU Construct, and several colleagues from both departments have designed a new fuel cell that is fully ceramic and is built by 3D printing. The printed structure is known as a triply periodic minimal surface (TPMS) and is mathematically optimized for maximum surface and minimum weight.

Their fuel cell—they call it a Monolithic Gyroidal Solid Oxide Cell or The Monolith for short—delivers more than one watt per gram. Not only is this a first, but it also broadens the field of possible fuel cell applications significantly, explains Nadimpalli, corresponding author of the study.

“Currently, using electricity-based energy conversion, such as batteries and fuel cells, doesn’t make sense for aerospace applications. But our new fuel cell design changes that. It’s the first to demonstrate the Watts to gram ratio—or specific power—needed for aerospace, while using a sustainable, green technology,” he says.

Extreme resilience

Fuel cells are nothing new, and their impact is evident in several sectors. While perhaps most visibly in hydrogen cars, they are, for example, also used as power supplies for hospitals and data centers, in ships, and as storage to stabilize renewable energy systems. Their ability to switch between power-generating and power-storing modes (electrolysis) makes them highly versatile in several applications.

There are many other reasons why the new fuel cells from the team of DTU scientists may be a game-changer. Apart from the weight being brought down significantly, the system allows gases to flow efficiently through the cell, improves heat distribution, and enhances mechanical stability. Switching to electrolysis mode, they produced hydrogen at nearly 10 times the rate of conventional designs.

“We also tested the system in , including temperature swings of 100°C, and repeatedly switched between and electrolysis modes. The fuel cells held up impressively, showing no signs of structural failure or layers separating,” says Esposito, corresponding author.

The researchers explain that this kind of resilience is vital for like NASA’s Mars Oxygen ISRU Experiment (MOXIE), which aims to produce oxygen from Mars’ carbon-dioxide-rich atmosphere.

This mission currently relies on bulky stacks weighing more than 6 tons. The new design could deliver a similar performance at 800 kg, which would significantly lower the costs of launching the equipment up there.

What makes this design especially compelling is not only its performance but also how it’s made, explains Nadimpalli, “While conventional SOC stacks require dozens of manufacturing steps and rely on multiple materials that degrade over time, our monolithic ceramic design is produced in just five steps, where we eliminate the metal and avoid fragile seals.

“Still, I believe that we can improve the system further using thinner electrolytes, cheaper current collectors, like silver or nickel instead of platinum, and even more compact designs.”

More information:
Zhipeng Zhou et al, Monolithic gyroidal solid oxide cells by additive manufacturing, Nature Energy (2025). DOI: 10.1038/s41560-025-01811-y

Yanhai Du, The power of the gyroid, Nature Energy (2025). DOI: 10.1038/s41560-025-01816-7

Citation:
3D-printed fuel cells could reshape sustainable aerospace applications (2025, September 21)
retrieved 21 September 2025
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15 Design-Forward DIY Tools Worth Upgrading to This Year

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15 Design-Forward DIY Tools Worth Upgrading to This Year


Something has shifted in the workshop. After years of DIY being sold as a weekend hobby for the mildly bored, home improvement has quietly become a serious cultural force. The global DIY market is forecast to hit nearly a trillion dollars this year. And while a third of you are apparently planning on starting a new DIY project in the next three months, the primary motivator for DIYers is, you guessed it, saving money. Not a bad thing right now, considering how the Iran war is spiking prices.

The tape measure and the drill you inherited from your folks will only take you so far. Fortunately, the tools driving this boom have never been smarter, and better hardware should mean, hopefully, better results. Whether you’re building furniture, finishing a deck, or just finally hanging that TV straight, the tools available right now are genuinely more precise than anything a generation ago could have imagined. From a miniaturized soldering station to a kid-safe desktop cardboard router, these are WIRED’s 15 picks worth making room for in your toolbox this year.

And no matter how good your tools are, never forget: measure twice, cut once.

A Multifunction Power Tool

Dremel

Blueprint 12V Multi-Drill

This intimidation-free power tool is perfect for people looking to conquer the multitude of household tasks that don’t require a massive hammer drill. Dremel’s neatly balanced 12-volt tool is made for fixing, tightening, and assembling. The detachable laser level and clever electronic stud finder hidden in the front of the handle make it ideal for hanging pictures, shelves, and 4K TVs. Comes with nine drivers and three drill bits, covering most household fixes without the need for a complete toolbox overhaul.

A Soldering Station

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A compact, open-source soldering workstation that condenses a full electronics bench into a single portable unit. The battery-powered soldering iron offers precise temperature control from 212 to 842 degrees Fahrenheit (100 to 450 Celsius), making it suitable for delicate PCB work as well as more robust tasks. Integrated fume extraction pulls harmful vapors away at the source, while built-in magnification and adjustable LED lighting improve visibility. The clincher is that by being open-source, Soldr positively welcomes hardware tweaks and firmware upgrades, making it as appealing to hobbyists as it is to serious prototypers.

A Sander

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Festool

DTSC 200 Basic Cordless Delta Sander

It is well known in the trades that if someone’s workshop is full of Festool gear, you can bet they take their craft seriously. And with its new 18 V cordless sander, the brand has made the possibility of achieving perfection just that bit faster. The triangular pad reaches deep into corners and tight edges, while variable speed control allows for fine-tuning between aggressive stock removal and ultrasmooth finishing. Weighing just over 2.4 lbs without the battery, the sander is designed for controlled, one-handed operation, while the integrated LED casts low-angle illumination across your work surface to highlight even the slightest imperfections. Connect it to a vacuum hose to keep the work table clean, or snap on the included dust collection bag and go fully mobile.

A Smarter Level

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Put the trundle wheel down; this modular, stackable touch screen measuring system combines laser distance, level, and rolling scale modules in one, measuring up to 164 feet of distance at a 1/16-inch accuracy. The system captures measurements in real time and syncs instantly to the app, allowing users to generate floor plans or mark up dimensions without manual note-taking. Compact enough to fit in a pocket yet precise enough for professional use, it’s a seriously smart upgrade for anyone still juggling tape measures and spirit levels.

A Premium Sewing Machine

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Husqvarna

Viking Designer Sapphire 85 Sewing & Embroidery Machine

While it might be overkill if you’ve not yet mastered the art of sewing buttons back on, this pro-grade smart sewing machine can do seriously impressive things with a needle and thread. It offers more than 680 stitch patterns through an 8-inch color touch screen for intuitive control, alongside automatic thread tension and sensor-based foot adjustments. The extended sewing surface allows for large quilting projects, while the powerful motor ensures consistent stitch quality across thick fabrics. Built-in connectivity and access to the mySewnet Library give you access to a continuously growing collection of embroidery designs, plus the ability to craft and implement your own.

A Box Cutter

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Designed by noted knife maker Richard Rogers, the Box Key applies his clean, minimalist approach to a tiny everyday cutter. The 1.24-inch drop point blade is made from Sandvik 12C27 steel with a stone-wash finish, which helps disguise scuffs from daily use while improving corrosion resistance. The stainless steel handle with a hole keeps the profile slim enough to attach to a key ring, and at 1 ounce, it adds barely any weight to your daily carry. A smart, indispensable little tool for opening boxes, trimming cord, and other light-duty jobs.

A Toolbox

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Japanese-inspired, UK-based Niwaki (translates as “garden tree”) produces seriously desirable and practical tools for home and garden. With the ST-Type Toolbox, however, the brand has created a vintage design that wouldn’t look out of place perched on a girder in the famous “Lunch Atop a Skyscraper” photo. Built from powder-coated steel with a traditional cantilever design, it measures 14.2 inches wide and opens to reveal tiered compartments that keep hand tools organized and visible. The metal dividers in the top trays can be rearranged to hold screws, nails, and bits, or removed entirely to fit even more tools.

Safety Glasses

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Pit Viper

Rev-Loc Z87+ Safety Glasses

Pit Viper may be famous for its right-wing-baiting anarchic approach to eyewear, but we bet you didn’t know it also does a fantastic range of equally irreverent-looking, but highly practical safety glasses. (This model will launch on April 13.) Certified to ANSI Z87+ standards, they have impact-resistant lenses, 100 percent UV protection, antifog coatings, plus adjustable arms and nose pieces for a super-secure fit. Available with standard- or high-contrast polarized lenses, the side shields can be removed when not needed.

A Handy Saw

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A good value, highly practical camp saw that folds small, but still cuts the mustard. The 12-inch blade is mounted on a four-pivot frame that maximizes usable cutting length and keeps tension consistent through each stroke. Then, when you’re done, it folds flat without disassembly, fully enclosing the blade for safe transport. Weighing 15.3 ounces, it is light enough for any expedition, but still feels reassuringly robust in use. That grippy rubberized textured handle works well in wet conditions, while thankfully, the design accepts standard 12-inch replacement blades.

A 3D Printer

Image may contain: Electronics, Mobile Phone, and Phone

This high-speed 3D printer is built for rapid prototyping, and so is aimed at designers who are tired of overnight prints for simple parts. It spits out building material at speeds of up to 1,200 millimeters per second, driven by a lightweight and accurate delta motion system. The enclosed cylindrical build chamber (12.6 x 16.9 inches) improves temperature stability for materials such as ABS and PETG, while auto-leveling and smart calibration should reduce setup time. A direct-drive extruder with an all-metal nozzle capable of reaching 350 Celsius supports a wide range of filaments. Wi-Fi, an onboard camera, and AI-assisted monitoring all help keep prints on track.

A DIY Stem Project

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CircuitMess

NASA Mars Perseverance Rover

The 1972 NASA Moon Buggy is one of only a handful of “products” WIRED has ever awarded a coveted 10/10 score to. It’s a shame you’ll never be able to get your hands on one, but you can always scratch that interstellar itch with this fantastic build-it-yourself Mars Perseverance Rover electronics kit. Designed for STEM learning, it combines more than 200 parts with coding, robotics, and mechanical assembly into a single project. Users can program movement, sensors, and basic autonomy through an included microcontroller, gaining hands-on experience with real-world engineering concepts. As intricate and detailed as it is, the whole model is remarkably smaller than the family cat.

A Leaf Blower

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Hoto

20V Cordless Leaf Blower

Bringing some much-needed sci-fi chic to yard work with this cordless 20-volt blower that pushes 720 cubic feet of air per minute at 120 mph from a lightweight body. The compact 3.7-pound design (without battery) makes it easy to use with one hand, even if you’re coping with trees post-leaf-peeping season. A brushless motor improves efficiency and extends the blower’s lifespan, while stepless speed control allows precise adjustment to give you just enough wind to clear light debris all the way up to a full-force clearing. The lithium-ion battery lasts up to 30 minutes, and it’s removable, so you can buy extra batteries to quickly swap in and keep on blowing.

A Charger and Radio

Image may contain: Electronics, Hardware, Computer Hardware, Stereo, Gas Pump, Machine, Pump, and Amplifier

Milwaukee

M18 Packout Radio Charger

Stackable with Milwaukee storage systems, this sound system has a classic rock-ready 10-speaker array capable of blasting The Boss to every corner of a construction site. Built tough and powered either by plugging it in or using the standard M18 battery, it has Bluetooth connectivity and an AM-FM radio. It also doubles as a battery and USB charger for smartphones and power tools. A reinforced housing protects it against drops, dust, and moisture.

An Electric Cutter

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A compact, battery-powered cutter designed to remove the effort and improve the precision of a host of cutting tasks. The motorized blade uses SK5 high-carbon steel slicers, delivering clean, controlled cuts through everything from cardboard and fabric to leather and even some plastics. Weighing 10.5 ounces, it is easy to guide with one hand, while the 4V rechargeable lithium battery should let you slice for hours on a single charge. A guarded cutting-edge and trigger activation improve control further, as well as keeping your fingers safe.

For the Kids

Image may contain: Furniture, and Indoors

This kid-safe router-style cutter is a perfect antidote to the usual screen time. Using a digitally controlled blunt cutting head rather than exposed blades, it lets children (big and small) cut cardboard, card, foam, felt, thin fabrics, and light plastics at either 1,500 rpm for faster cuts or 800 rpm for more controlled work. The standard head can handle materials up to 3 mm thick, but an optional upgrade to a 5 mm “ProCut” head lets you go thicker. The compact 11.8 x 11.8-inch desktop unit comes in pink or green (go pink!) and connects over USB or Wi-Fi to bundled software that can generate cutting templates from simple project designs you upload. The Cutter 2 serves up fun and engaging activities for little ones as young as four.



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Artemis II Mission Launches Successfully

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Artemis II Mission Launches Successfully


At 6:36 pm Cape Canaveral time, NASA’s SLS rocket lifted off without incident with the four members of the Artemis II spacecraft aboard. During the first few hours, Orion will complete its journey into Earth orbit and, throughout the first day, will conduct critical navigation and systems tests. Around the third or fourth day, the spacecraft will begin its trajectory toward the moon and cross its gravitational sphere of influence. In total, the mission will last approximately 10 days.

The mission includes the first woman and the first Black person on a crewed mission to lunar orbit. The launch comes 53 years after Apollo 17, the last crewed mission to the Moon.

The Artemis II crew will not land on the moon (that will happen on Artemis IV ). Instead, their capsule will fly at altitudes between 6,000 and 9,000 kilometers above the surface of the far side of the moon, circle it, and begin the return journey to Earth. The mission’s main objective is to demonstrate that the space agency has the technological capability to send people to the Moon safely and without incident.

Once they achieve this, NASA will begin preparations for new moon landings in the following years, which will aim to establish the first lunar bases in history and, with them, the sustained and sustainable presence of humans on the satellite.

The launch was successful and occurred on schedule. The launch window opened on Wednesday, April 1, at 6:24 pm Eastern Time (EDT) and could have been extended for two hours, if necessary. NASA would have had five more days to attempt another launch.

Mission Details

The astronauts took off on a NASA SLS rocket and are traveling inside the Orion capsule, described as a spacecraft about the size of a large van. They will orbit Earth for at least two days to test the onboard instruments. Then they will align the spacecraft to begin its journey to the moon. By the fifth or sixth day of flight, the capsule is expected to enter the moon’s sphere of influence, where the satellite’s gravity is stronger than Earth’s, and dock with its orbit.

When the spacecraft passes “behind” the moon, the most dangerous phase will begin. The crew will be out of contact with Earth for about 50 minutes due to interference from the moon itself. During this crucial moment, the crew must capture images and data from the moon, taking advantage of the far-more-advanced technology they carry than was available during the Apollo era.

After completing the return, the capsule will head home, taking advantage of the Earth-moon gravity field to save fuel. According to NASA estimates, by the 10th day of flight the crew will be close to reaching the planet.



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Arm works with IBM to deliver flexibility on mainframe | Computer Weekly

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Arm works with IBM to deliver flexibility on mainframe | Computer Weekly


IBM has begun working with chipmaker Arm to develop what it calls dual-architecture hardware to provide flexibility when running enterprise artificial intelligence (AI) and data-intensive workloads.

Their overall goal is to combine IBM’s experience in systems reliability, security and scalability that it offers on Z-series mainframe systems with Arm’s expertise in power-efficient architectures and supporting a broad software ecosystem to build flexible and scalable computing platforms for the future.

Arm has been on a path to deliver an alternative to x86-powered servers in the datacentre. The company has introduced the Arm Agentic AI (artificial intelligence) central processor unit (CPU) which it positions as a processor that is tasked with keeping distributed AI systems operating efficiently at scale. This includes orchestrating AI accelerators, managing memory and storage, scheduling workloads and moving data across systems.

This latest collaboration appears to be focused on deliver enterprise reliability to the Arm platform. It builds on IBM’s heritage of offering coprocessors for the Z-series hardware such as the Integrated Facility for Linux, which was introduced in 2000. The mainframe manufacturer later introduced a Linux system based on the Z-series architecture, called LinuxOne, designed to let enterprise customers run Linux workloads in situ with data that resides on the mainframe system.

Christian Jacobi, chief technology officer and IBM fellow of IBM systems development, said: “This moment marks the latest step in our innovation journey for future generations of our IBM Z and LinuxOne systems, reinforcing our end-to-end system design as a powerful advantage.”

Mohamed Awad, executive vice-president of the cloud AI business unit at Arm, said: “Our collaboration with IBM builds on this progress, extending the Arm ecosystem into mission-critical enterprise environments and giving organisations greater flexibility in how they deploy and scale these workloads.”

The two companies said they are exploring how to expand virtualisation technologies that allow Arm-based software environments to operate within IBM’s enterprise computing platforms. According to IBM and Arm, this work is designed to expand software compatibility and streamline how developers and enterprises bring Arm applications into mission-critical environments. 

In the security and reliability front, the pair plan to investigate new ways to support the performance and efficiency demands of modern workloads, including AI and data-intensive applications. IBM and Arm said they will be looking at how to enable enterprise systems to recognise and execute Arm applications. 

The two companies also hope to provide a broader software ecosystems and greater flexibility in how applications are deployed and managed. IBM plans to offer new systems for its customers that incorporate Arm’s technology.

Tina Tarquinio, chief product officer of IBM Z and LinuxONE, said: “Our aim is to expand software choice and improve system performance while maintaining the reliability and security our clients expect.” 

The collaboration is seen as a signal of how enterprises may eventually deploy scalable, flexible IT infrastructure to support different types of application workload.

Patrick Moorhead, founder, CEO and chief analyst at Moor Insights & Strategy, added: “What IBM and Arm are signaling here is a meaningful step toward that future that could broaden how enterprises think about deploying and scaling modern workloads. While the full implications will take time to unfold, it’s clear this reflects a deeper level of investment in long-term platform innovation and ecosystem expansion than we typically see at this stage.” 



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