3D-Printed Graphite and SiC Reactors for CO₂-Free Hydrogen Production

BRIGHT Group

3D-Printed Graphite and SiC Reactors for CO₂-Free Hydrogen Production

CO₂-free hydrogen production through methane cracking, splitting methane into hydrogen and solid carbon.
3D-printed reactor structures made of graphite or silicon carbide (SiC) using the binder jetting process.
Highly complex, porous reactor geometries, including periodic open-cell structures such as gyroid / POCS.
Integrated reactor, heating element, and catalyst function within the same structure during the methane-cracking process.
Scalable implementation, from prototype development to pilot and industrial applications, supported through contract manufacturing or system technology.

3D-Printed Graphite and SiC Reactors for CO₂-Free Hydrogen Production

BRIGHT’s additively manufactured reactors made of graphite or silicon carbide (SiC) enable innovative and climate-friendly hydrogen production through methane cracking.
Using the binder jetting process, highly complex, porous reactor geometries are produced, allowing efficient internal heating and the CO₂-free splitting of methane into hydrogen and solid carbon.
The challenge is that conventional processes for hydrogen production are associated with high CO₂ emissions and significant energy losses.
At the same time, traditional manufacturing methods quickly reach technical and economic limits when producing complex, highly porous reactor structures made of graphite or SiC.
Our solution uses the binder jetting process to produce high-precision reactors with periodic open-cell structures, e.g., gyroid structures. In the methane-cracking process, these structures function simultaneously as the reactor structure, heating element, and catalyst, enabling efficient, scalable, and CO₂-free hydrogen production.
BRIGHT offers this technology together with its 3D printing partner AM Pioneers and supports customers both through contract manufacturing on binder jetting systems in Esslingen and Slovakia, as well as through the sale of system technology for producing reactors made of graphite or silicon carbide (SiC).

Key features

Additively manufactured reactors made of graphite or SiC
CO₂-free hydrogen production through methane cracking
Highly porous, complex cell structures, gyroid / POCS
Internal Joule heating for high energy efficiency
Scalable from prototypes to industrial applications

Application areas

Hydrogen production from methane
Energy technology and Power-to-X applications
Chemical reactors for high-temperature processes
Research and development projects in sustainable process industries
Pilot and industrial plants for climate-friendly hydrogen technologies

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BRIGHT Group

The BRIGHT Group is an alliance of leading technology companies combining key competencies to support R&D departments across the mobility sector - from the automotive and defence industry, to aerospace and to agricultural and off-highway machinery. We partner with our clients to tackle the challenges brought by transformation, thinking across technologies, systems, and interfaces.

Our expertise lies in the areas of drive systems, system electronics, vehicle networking and hydrogen technologies.

Vehicle conversion and vehicle construction: We offer professional vehicle conversion and construction for individual requirements – from special-purpose vehicles to official vehicles. We combine technology and design from a single source: from sound planning to precise implementation. Our certified processes guarantee the highest quality, reliability and maximum process safety in every project.

Test and measurement technology for systems & components: Our focus is on testing and measurement technology for systems and components. We offer comprehensive services to ensure the quality and reliability of your products. Our experienced team is at your side to fulfil the specific requirements of your project.

Cable harness development and wire harness construction: Our core expertise lies in the customised development and production of cable and wire harnesses. We offer individual solutions that meet the highest quality standards and fulfil the specific requirements of our customers.

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