James Cropper’s Resillion™ Coating Technology Outperforms DOE Benchmark to Address PEM Electrolyser Degradation

James Cropper Advanced Materials is supporting the development of green hydrogen technologies by improving the durability and efficiency of core electrolyser components.

New performance data reveals that RESILLION™ technology – a high-performance coating for titanium PEM electrolyser components – significantly reduces degradation in critical components such as Bipolar Plates (BPP) and Porous Transport Layers (PTL). By lowering degradation rates to just 3.9 μV/h, RESILLION™ outperforms the U.S. Department of Energy’s benchmark of 4.8 μV/h, delivering lifetime savings exceeding $430,000 in a 5MW electrolyser system operating over 80,000 hours.

Understanding degradation mechanisms is essential for maintaining system efficiency and extending the operational life of PEM electrolysers. Dr. Srijita Nundy, Head of Innovation at James Cropper Advanced Materials, explains:

Dr. Srijita Nundy

Head of Innovation

“ Degradation is one of the most critical factors impacting electrolyser performance. At James Cropper, we’ve gone beyond surface-level testing. Our in-depth research into degradation mechanisms allows us to offer solutions that not only meets but exceeds industry expectations, empowering our customers to achieve greater efficiency and cost-effectiveness. ”

Dr. Srijita Nundy

Head of Innovation

To understand the full life cycle of PEM Electrolysers, Dr. Nundy and her team of electrochemists have developed a state-of-the-art, custom-built testing facility that replicates real-world electrolyser conditions. This in-house capability enables the company to accelerate development cycles, validate performance under extreme conditions, and drive data-led improvements across the hydrogen value chain.

The latest study also demonstrates how RESILLION™ mitigates key degradation pathways, contributing to longer component life and improved system reliability. These advancements reduce maintenance and replacement costs, supporting the broader adoption of hydrogen as a scalable, clean energy solution.

With RESILLION™, James Cropper reinforces its position at the forefront of the hydrogen economy—delivering technologies that are not only innovative but indispensable for a sustainable energy future.

CASE STUDY

Reducing Degradation in PEM Electrolysers with Resillion™ Technology

Backed by real-world data and advanced materials science, this case study unveils how RESILLION™ significantly outperforms DOE benchmarks, minimising degradation, extending component life and enabling long-term savings in PEM electrolyser systems.

DOWNLOAD THE FULL CASE STUDY

EVENT

Hydrogen Technology Expo, Houston 2025

James Cropper will be showcasing RESILLION™ on Booth 660 at the Hydrogen Technology Expo, Houston from 25-26 June. Also on display will be Ready2Stack™, a new drop-in bipolar plate (BPP) solution which incorporates RESILLION™ technology and is designed to simplify supply and ensure optimised BPP design and stack performance. To find out more about reducing electrolyser degradation rate and improving efficiency visit the James Cropper team at the show.

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