3D printing of asymmetric YSZ electrolyte membranes with enhanced integrity via protective resin coating

The development of novel dense electrolyte membranes via three-dimensional printing (3DP) has garnered increasing attention for enabling high-performance solid oxide cells (SOCs). In this study, asymmetric yttria-stabilized zirconia (YSZ) electrolyte membranes featuring triply periodic minimal surface (TPMS) lattice structures were designed and fabricated using digital light processing (DLP) 3DP. To address cracking issues in the printed green bodies during drying and storage, a novel post-processing strategy involving a protective resin coating was introduced. By applying a thin layer of photocurable resin and curing it in situ, a robust protective barrier was formed, which enhanced structural integrity and significantly mitigated drying-induced defects. Owing to the asymmetric structure, the ionic conductance of the YSZ electrolyte membranes at 800 °C increased markedly from 0.13 S to over 5.38 S. This strategy demonstrates significant potential for the rapid and reliable fabrication of high-quality YSZ electrolytes via 3DP.