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DIY fuel cell

Hackaday Prize Semifinalist: A Low-Cost DIY Hydrogen Fuel Cell

A 2015 Hackaday Prize project proposed a compact hydrogen fuel cell using para-aramid cloth and asphaltenes. Its reported 20 A at 18 V was a theoretical prediction, not verified performance.

By Bettesworth Construction Team 2 min read
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In a September 4, 2015 feature, Hackaday described a Hackaday Prize project proposing a compact, low-cost hydrogen fuel cell built with experimental materials. Its often-quoted output—20 A at 18 V—was a prediction, not a demonstrated or independently verified result. The distinction matters: the project is a snapshot of an experimental design, not evidence of a working product or a ready-to-build system.

What the 2015 project proposed

Hackaday’s Brian Benchoff reported that the project used sulfonated para-aramids—described in the article as Kevlar cloth—as the proton carrier, or membrane, in the cell. The proposed active layer was asphaltenes, which the article characterized as a waste product from tar-sands extraction. The concept was presented as an alternative materials experiment for a hydrogen fuel cell, rather than as a commercially available design.

The article said the cell could fit in the palm of a hand. That description referred to the cell itself, not an entire operating system: Hackaday explicitly excluded the hydrogen tanks and other system components from its description of the predicted output.

What the output figures mean

Hackaday reported a predicted output of 20 A at 18 V. Those figures should not be read as measured performance. In the comments on September 4, 2015, the project creator, posting as Lupus Mechanicus, described the figure as a theoretical limit and wrote: “That’s theoretical limit, 0.9v and 200mA per square cm of exchange membrane.” This was the creator’s statement, not an independent test or validation.

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The source provides no test data establishing that the cell reached the predicted output, and no basis for calculating efficiency, durability, operating life, or real-world system output. The figures also do not include the hydrogen tanks and associated equipment needed for a complete system.

Materials and design status at publication

The project’s proposed membrane material was sulfonated para-aramid cloth; the active layer was described as asphaltenes. In the same comment thread, Lupus Mechanicus said he was considering chitosan as a thinner proton-transport membrane. That comment indicates the membrane approach was still being reconsidered when the feature appeared. It does not establish that chitosan became part of a final design or what happened to the project afterward.

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Hackaday’s article also mentions conventional platinum electrodes, but it gives no comparable cost, durability, efficiency, or performance figures for platinum, the proposed para-aramid approach, or chitosan. The available account therefore supports describing the experimental materials, not ranking them or concluding that one is cheaper or better.

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What readers can—and cannot—conclude

  • Established by the article: In 2015, a Hackaday Prize entry proposed a hydrogen fuel cell using sulfonated para-aramid cloth as a proton carrier and asphaltenes as an active layer.
  • Not established: That the cell produced 20 A at 18 V, or that any of the stated theoretical figures were independently measured.
  • Not established: A final material configuration, full-system design, safe construction procedure, or later project outcome.

The feature is useful as a record of an experimental idea and its proposed materials. It is not a construction plan: the article and comments do not provide validated operating data or instructions for safely building or operating a hydrogen system. Readers should not treat the proposed output or palm-sized form factor as evidence that a complete, practical fuel-cell setup was demonstrated.

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