Advances and challenges in micro-porous layer design for commercialization of proton exchange membrane fuel cell

As global efforts to mitigate climate change intensify, proton exchange membrane fuel cells (PEMFCs) have become a cornerstone of low-carbon energy systems. At the core of PEMFC performance and durability is the micro-porous layer (MPL), a critical component that facilitates mass and electron transport, water management, and mechanical stability. Despite its importance, MPL research has been comparatively underexplored, with limited comprehensive reviews discussing its current advancements and future directions. This review bridges the gap by thoroughly analyzing MPL materials, structures, mechanisms, performance, and evaluation methods from academic and industrial perspectives. It highlights the contributions of high-dimensional carbon materials and advanced manufacturing techniques to enhancing MPL performance while identifying challenges such as the degradation of hydrophobic materials during long-term operation. It investigates the current state of industrial production and scalability. MPL development is expected to benefit from sustainable innovations and advancements driven by artificial intelligence, enabling future breakthroughs in material design and manufacturing technologies. By balancing performance and cost, MPL advancements have the potential to transform academic progress into practical industrial applications, accelerating PEMFC commercialization and supporting global carbon neutrality goals.