Engineered flow fields for enhanced vanadium redox flow battery performance using topology optimization

We report the first experimental implementation of a topology-optimized flow field design in vanadium redox flow batteries (VRFBs). Using a pseudo-2D numerical model, we generated a branched, interdigitated-like structure reminiscent of natural transport networks. The design was fabricated onto graphite bipolar plates and tested against conventional interdigitated flow fields under varying electrolyte flow rates. At relatively high flow rates, the topology-optimized design improved power density by 17–30 %, consistently providing higher voltage efficiency while maintaining a lower pressure drop. We also observed uniform pressure distribution and reduced electrode compression during assembly, attributed to the branched design. While gravitational effects limit performance at relatively low flow rates, the overall results demonstrate that topology optimization offers a compelling strategy for improving mass transport and cell efficiency. This approach opens new directions for nature-inspired design in electrochemical energy systems.