Engineer’s Guide to Hydrogen: Wire mesh solutions for more efficient electrolysis, H₂ filtration, and scalable industrial hydrogen processes

Industrial hydrogen production requires materials that withstand chemical, thermal, and mechanical loads – while also being suitable for reproducible series manufacturing. The Engineer’s Guide explains how 3D wire mesh stabilizes water and gas transport in PEM and AEM stacks, how specialized nickel mesh improves electrode performance in AEL systems, and how multilayer mesh laminates ensure reliable filtration at pressures exceeding 700 bar. These properties have a direct positive impact on efficiency, service life, and operating costs – and become increasingly important as scaling continues.

HyVentus case study: 3D PTL mesh for higher-performance PEM / AEM electrolysers

A notable example is the HyVentus research project, in which Haver & Boecker developed a three‑dimensional PTL mesh made of titanium. Its geometry prevents gas bubble entrapment and improves membrane contact. At the same time, the mesh is suitable for continuous production processes – a key step toward series-ready gigafactory manufacturing.

Precision that drives H₂ processes forward

The clearly definable geometry of wire mesh enables precise simulation of volume flows, velocities, pressures, temperature profiles, and flow lines – a decisive advantage when designing efficient H₂ processes. “With the Engineer’s Guide, we provide engineers with a tool that highlights the technical relevance of wire mesh throughout the entire value chain and presents the functionality and cost efficiency of our solutions in a balanced and accessible way,” explains Lars Wegner, Hydrogen Project Manager at Haver & Boecker.

The guide is aimed at development and system engineers, design engineers, and process engineers in electrolysis and filtration applications, as well as component manufacturers, plant builders, and technical‑strategic decision-makers – in other words, anyone who needs robust, scalable, and economical solutions for industrial ramp-up. The Engineer’s Guide is available free of charge and accessible digitally.