Electrochemical energy systems, especially redox-flow batteries for stationary energy storage and electrolyzers, face a scalability bottleneck driven by complex, costly, and poorly optimized reactor (stack) architectures. Despite major investment and advances in chemistry, many designs remain direct scale-ups of laboratory hardware, relying on graphite/metal parts and multi-component assemblies that constrain design freedom, increase cost, and hinder manufacturability and rapid iteration. As a result, performance and reliability fall short of their true potential, delaying industrial adoption and large-scale deployment of energy-storage and conversion technologies.
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