Nanostructured Thin Film Electrocatalysts - Current Status and Future Potential

3M's nanostructured thin film (NSTF) catalyst technology platform is the only practical example of an extended surface area catalyst which significantly reduces many performance, cost and durability barriers facing electrodes for H2/air PEM fuel cells for vehicles. In this paper we first discuss the recent gains in NSTF alloy ORR activities from both materials and process improvements, followed by accelerated durability tests of MEA's with these catalyst improvements. Next we discuss recent progress in tailoring NSTF anode catalysts with ultra-low precious group metal oxygen evolution reaction (OER) catalysts for high tolerance to automotive start up/shut down and cell reversal events. We follow with our progress in developing strategies and anode GDL's for optimized fuel cell water management for automotive low temperature operation. Finally we discuss a path forward to achieve the entitlement NSTF activity and comment on critical durability issues intrinsic to ultra-low loading catalysts.