NASA’s latest experiment could pave the way for in-depth explorations of the Moon and Mars. Carried out at NASA’s Fuel Cell Test Laboratory in Cleveland, Ohio, the project aims to build a new regenerative fuel cell that could change the way NASA conducts its lunar missions. Similar to a rechargeable battery that combines and splits hydrogen and oxygen to produce electricity, NASA hopes the fuel cell will solve critical problems when exploring the far side of the Moon, where solar power is ineffective due to the Moon’s two-week rotations. Such limitations have prompted the agency to research nuclear reactors and other novel energy systems for possible lunar bases.
These experiments come as NASA’s Artemis program moves closer to restoring human presence on the lunar surface. Earlier this year, NASA took a major step in its return to the Moon when the Artemis II mission sent four astronauts on a nine-day journey around the Moon, the first crewed mission of its new deep space project. The agency’s next Artemis mission, planned for 2027, will test commercial landers in low Earth orbit, a major step toward NASA’s planned return to the Moon in 2028.
NASA hopes its regenerative fuel cells will help establish a long-term presence on the lunar surface. Scientists involved in the project praised its diverse uses in lunar exploration, as “an ideal technology for habitats, exploration with rovers, and many of the systems envisioned under Artemis,” according to Dr. Kerrigan Cain, chief engineer at NASA’s Glenn Research Center. “Developing a long-term, sustainable human presence on the Moon requires energy and energy storage solutions tailored to these needs. Regenerative fuel cells fit perfectly into this puzzle.”
Inside NASA’s Regenerative Fuel Cells
NASA’s regenerative fuel cell system, lovingly described by Cain as “a monster,” is about the size of a small sedan. Although it contains 270 sensors and around 1,000 components, scientists praise its relatively light weight compared to battery systems of similar capacity. The cell works by combining hydrogen and oxygen to create electricity, heat and water. To “recharge,” the cell splits the water into oxygen and hydrogen, allowing the refueling process to continue. Unfortunately, charging efficiency still sees a substantial decline. As it stands, the battery will use a photovoltaic generator or other external power source to power this charging system.
Testing the machine is not an easy task. The cylindrical fuel cell, which NASA describes as “a stack of flattened silver and gold soda cans grouped together,” must be lifted via a small crane. Once secure, scientists conduct experiments remotely via a control room. Starting in 2019, the researchers achieved several key milestones towards reaching the planned completion date of September 2027. Currently, the team is working on storing the gases produced by their new recharging system. Ultimately, Dr. Cain’s team hopes to move testing procedures outside of usual laboratory settings to real-world analogues of the harsh conditions of the lunar surface.
In addition to the NASA Glenn Research Center team, the agency has teamed up with two innovative industry partners at the forefront of regenerative fuel cell technologies. The first, Giner, Inc., partnered with NASA to build water electrolyzers. Infinity Fuel Cell and Hydrogen, Inc., the other private sector partner, have delivered their regenerative fuel cell prototype with at least 500 hours of battery life in 2024.
Regenerating NASA’s Moon Thrust
The Moon presents several challenges to NASA engineers seeking to power long-term bases and exploration projects. In particular, the fourteen-day night and day cycles pose several problems for lunar exploration. On the one hand, extreme temperatures that range from 292 degrees below zero to 248 degrees Fahrenheit can create precarious conditions. Additionally, the lack of consistent sunlight eliminates solar power as a reasonable energy option. That’s why NASA is looking for new refueling systems that will allow rovers and their habitats to survive the harsh lunar conditions.
Developing sufficient regenerative fuel cell technologies could be crucial to realizing NASA’s plans for extended lunar missions. Traditional lithium-ion batteries lack the energy density to power extended missions and require expensive charging infrastructure. Regenerative fuel cells can hold up to 3.4 times the storage capacity of batteries of the same mass. Nuclear options, which have become increasingly popular in lunar base discussions, still face important situational limitations. As it stands, no existing technology can sustain operations for an entire lunar night. But the agency hopes its regenerative fuel cell program can reverse the trend.
NASA scientists hope their energy storage system will be operational for the agency’s upcoming Artemis missions. With a moon landing planned for early 2028 and sustained lunar mission operations planned for late 2028 and beyond, the agency hopes to establish its first lunar base by 2030. Seventy-nine launches, up to five surface habitats and $30 billion later, NASA hopes to erect the first permanent lunar colony within a decade. Regenerative fuel cells will likely play a critical role in realizing these grandiose ambitions.
