Supercharging Electrolyzers: SunGreen

:: Advanced materials · Nanoengineered electrodes

More output. Less energy. No platinum or rare earths.

SunGreen stacks reach ~90% HHV efficiency with zero platinum-group metals — twice the output at half the cost, independently validated and running in commercial AEM systems today. The NanoFuzeX™ platform behind them fuses catalyst into porous metal with the nanostructure intact.

Patent-pending catalyst compositions and stack designs across major markets · proprietary process know-how proven in commercial production

:: Why now

The industry over-built capacity. It will be sorted on efficiency.

Global electrolyser manufacturing capacity has reached roughly 25 GW a year while installed capacity sits near 4 GW — Western lines run at 10–20% utilisation, and projects are being cancelled where returns no longer clear. The market is not rejecting hydrogen. It is rejecting weak economics.

Undifferentiated capacity is not the scarce asset. Efficiency is. Every point of stack efficiency moves the levelised cost of hydrogen, and every gram of iridium removed takes a supply-chain risk off the balance sheet. That is the ground SunGreen was built to compete on.

:: The platform

Bonded at full metallic contact. Nanostructure intact.

Every high-performance material faces the same constraint: it must be fixed to a substrate, at loading, without losing the properties that made it valuable. Coating preserves the nanostructure but insulates it behind polymer binder. Conventional fusing bonds the material but coarsens the nanostructure away. The NanoFuzeX™ platform does neither — it fuses catalyst into the substrate and brings the nanostructure through intact.

Stage 01

Catalyst material

Stage 02

The NanoFuzeX™ platform

Stage 03

Finished electrode

The result is a metallurgically fused, binder-free catalyst layer bonded through a porous metal skeleton — conductive end to end, mechanically locked, and stable where conventional coatings delaminate.

:: NanoFuzeX™ platform

Proven in hydrogen. Built for more.

The platform was engineered from day one to deliver nanoengineered electrodes across multiple applications, not for a single market. Green hydrogen is the beachhead — validated, delivered, and operating in AEM systems at MW-scale commercial deployments, with extensive third-party testing completed at world-renowned research and testing laboratories. The same platform extends to five adjacent electrochemical markets, each at a different stage of engagement.

Beachhead · proven at MW scale

Alkaline & AEM electrolysis

~90% HHV stack efficiency with zero platinum-group metals — double the output at 20% lower energy, independently validated and running in commercial systems today.

Adjacent · carbon

CO₂ conversion & e-fuels

Gas-diffusion electrodes where durability at current density decides the unit economics of every e-fuel molecule.

Adjacent · water

Electro-oxidation & PFAS

Durable fused anodes as an alternative to boron-doped diamond — the most expensive electrode in industry.

Adjacent · storage

Nickel batteries

Nickel plaque electrodes are the incumbent in Ni-H₂, Ni-Cd and Ni-Zn cells — and precisely what the platform delivers.

Adjacent · chemicals

Structured hydrogenation catalysts

Fused catalyst inserts for continuous-flow hydrogenation, where packed beds channel and coated mixers fade.

Adjacent · ammonia

Urea & ammonia oxidation

Treat the wastewater and make hydrogen from it. Two revenue streams, one electrode stack.

:: Products

Proven products. Ready to specify.

SunGreen's electrode line, porous transport layers and complete stacks — proven at commercial scale in green hydrogen.

Electrodes

Catalyst-coated electrodes

Ultra-stable, high-performance fused electrodes for alkaline, AEM and adjacent electrochemistry — binder-free, free of platinum-group metals, and stable at very high current densities.

Anode · cathode · custom formats

Transport layers

Porous transport layers

Nanostructured PTLs engineered for transport and bubble management, matched to SunGreen electrode chemistry or built to customer specification.

Nickel & titanium substrates

Stacks

Electrolyser cell stacks

~90% HHV efficiency with no PGM materials, in 2, 20 and 200 kW stack sizes — available as stack only or as a complete system.

2 kW · 20 kW · 200 kW

:: Validated in the field

More than a materials supplier. A route to commercial scale.

SunGreen electrodes are not a laboratory result. They operate in commercial AEM systems at MW scale, have completed extensive third-party testing at world-renowned research and testing laboratories, and are backed by manufacturing capacity already in place and operating. Validation and volume production run on the same line.

:: SERVICES

Three routes to market.

SunGreen sells finished electrodes and stacks, licenses the technology and stack designs to manufacturers whose volumes exceed any single factory, and manufactures under toll for customer-supplied catalysts. Licensing is how the platform reaches gigawatt scale without gigawatt capital.

Technology & stack licensing

SunGreen's electrode manufacturing technology can be licensed and transferred into an existing production line, with materials supply and a royalty per m² — the established model in electrode manufacturing, and the only way volumes beyond a single factory are served.
‍
For AEM and CO₂ electrolysis, SunGreen also licenses its stack designs, with the underlying electrodes supplied by SunGreen. The designs are membrane-agnostic and pair with any membrane the licensee has already qualified.

Manufacturers · OEMs at scale

Toll manufacturing — the electrode foundry

Customers supply the catalyst material. SunGreen returns finished electrodes in the specified geometry, under the customer's brand. The composition remains the customer's; the platform remains SunGreen's. Neither party discloses to the other.

It is the fastest route from a validated material to a working device, without the capital, hiring and lead time required to build a coating line.

Catalyst makers · developers · OEMs without a coating line

Validation & testing

Characterisation and electrochemical performance testing that produces decision-quality data — XRD, SEM, adhesion and full electrochemical evaluation, delivered as a documented report suitable for board, customer or investor review.

Available as a standalone service or as the first step of a manufacturing programme.

R&D teams · materials developers

:: Capability

Capacity ready today. Room to grow with you.

SunGreen's commercial line is built, commissioned and operating today, with capacity scaling toward 10,000 m² a year — approximately 100 MW of electrode — by 2027.

Capacity

Scaling to 10,000 m² / year by 2027

Location

Singapore / SE Asia · Melbourne

Electrode size

300 cm² · 560 cm² · 2,200 cm² · up to 1–3 m²

Formats

Rectangular · round discs · custom geometries

Substrates

Porous nickel foam · felt · fibre · mesh · titanium felt & fibre

Trial scale

Custom electrodes: from 50–100 g of customer powder · Ready-made products: samples in 5, 25, 100 cm²

Characterisation

Custom qualification: XRD · SEM · adhesion · electrochemical performance testing · Ready-made products: electrochemical performance & QC data

Whether you're scaling a custom-fused electrode from a first sample, or ordering volume of an already-qualified product, it runs on the same line and the same platform — no technology transfer, no re-qualification of a new method.

:: Partnering

From material to production, de-risked.

A partnership built on technical depth and transparency. Given a material and its performance requirement, SunGreen establishes with data whether it can become an electrode, and what production at volume requires.

Phase 01

Qualification

From a 50–100 g sample, SunGreen screens the material to establish the most optimal process for the chemistry, and returns test coupons with a full characterisation report.

~4 weeks · fixed fee, creditable

Phase 02

First article

A pilot batch of finished electrodes in the specified geometry. Catalyst material is free-issued by the customer; substrates and all other materials are supplied by SunGreen.

4–6 weeks · priced per piece

Phase 03

Production

Ongoing supply from the SunGreen line, under the customer's brand, with rates that step down against committed annual volume — or a licence, where volumes require one.

Ongoing · priced per m²

A partner that protects quality, protects material, and protects IP. Customer formulations never leave the agreement. The NanoFuzeX™ platform never leaves the SunGreen line.

:: Why SunGreen

Trusted by industry. Validated by science.

SunGreen electrodes are specified by global energy and engineering companies, independently tested by leading research institutions, and operating in commercial systems today.

Partners