Next-generation leak detection systems for hydrogen

Challenge

As the hydrogen economy gains momentum, the demand for reliable, robust, and industrial-grade sensor technology is growing. Hydrogen is highly flammable, highly diffusible, poses a safety risk even at low concentrations, and is difficult to detect. Existing sensor technologies are reaching their limits, particularly in terms of long-term stability, selectivity, miniaturization, cost, and integration. At the same time, there is a great need to rapidly translate research results into marketable products in order to promptly safeguard industry and infrastructure.

Solution 

The Fraunhofer Institute for Thin Film and Surface Technology IST is developing innovative material- and coating-based sensor concepts for hydrogen detection. The core foundation consisted of nanostructured functional layers whose hydrogen sensitivity was specifically tuned through material selection, layer design, and coating parameters. By combining coating technology, surface functionalization, and sensor system integration, highly sensitive yet robust sensor elements were realized.

At the same time, efforts to bring the technology to market were accelerated: In collaboration with the spin-off Integrative Nanotech, the layer-based sensor technologies developed at Fraunhofer IST are being industrialized, scaled up, and adapted to specific applications—ranging from leak detection to in-process hydrogen measurement. This collaboration has made it possible to combine scientific excellence with entrepreneurial agility.

Added Value 

The developed sensors enable early and reliable hydrogen detection, thereby increasing safety in industry and infrastructure. Based on functionalized sensor layers, they are characterized by high measurement stability, selectivity, and integrability. Partners benefit from proven technologies, reduced development risk, and accelerated technology transfer. With Integrative Nanotech, market launch is being consistently driven forward.