Hydrogen Economy and Climate Change: Additive Manufacturing in Perspective

The hydrogen economy stands at the forefront of the global energy transition, and additive manufacturing (AM) is increasingly recognized as a critical enabler of this transformation. AM offers unique capabilities for improving the performance and durability of hydrogen energy components through rapid prototyping, topology optimization, functional integration of cooling channels, and the fabrication of intricate, hierarchical, structured pores with precisely controlled connectivity. These features facilitate efficient heat and mass transfer, thereby improving hydrogen production, storage, and utilization efficiency. Furthermore, AM’s multi-material and functionally graded printing capability holds promise for producing components with tailored properties to mitigate hydrogen embrittlement, significantly extending operational lifespan. Collectively, these advances suggest that AM could lower manufacturing costs for hydrogen-related systems while improving performance and reliability. However, the current literature provides limited evidence on the integrated techno-economic advantages of AM in hydrogen applications, posing a significant barrier to large-scale industrial adoption. At present, the technological readiness level (TRL) of AM-based hydrogen components is estimated to be 4–5, reflecting laboratory-scale progress but underscoring the need for further development, validation and industrial-scale demonstration before commercialization can be realized.