Open Source Electrolyzer

100 kW Open Source Alkaline Electrolyzer Stack – Bill of Materials

Component	Specification	Quantity	Typical Cost Range	Example Supplier / Source	Link
Nickel Foam (Cathode)	1–2 mm thick, 20–60 PPI, >99% Ni	~12 m²	$300–$1,500	MTI Corporation	https://mtixtl.com/products/0-5-mm-thick-nickel-foam-for-battery-cathode-substrate-or-solid-state-electrolyte-support-l-1000-x-w-200-mm-eq-bcnf-05m
Nickel Foam (Anode substrate)	same spec as cathode	~12 m²	$300–$1,500	Goodfellow	https://www.goodfellow.com/usa/nickel-sizes-foam-group
Separator (Zirfon-type diaphragm)	~0.3–0.5 mm polysulfone + zirconia composite	~12 m²	~$1,800	Agfa Zirfon PERL	https://www.agfa.com/zirfon/
Cell Frames / Spacers	HDPE / polypropylene plates	~100 pieces	$500–$1,500	McMaster-Carr plastic sheet	https://www.mcmaster.com/polypropylene-sheets/
End Plates	Carbon steel or stainless plate	2 pieces	$200–$600	Online Metals steel plate	https://www.onlinemetals.com/
Gaskets	EPDM or PTFE sheet 1–2 mm	~100 sets	$100–$400	McMaster-Carr gasket sheet	https://www.mcmaster.com/epdm-rubber/
Current Collectors	Nickel sheet or nickel mesh	~2–4 m²	$200–$800	Alfa Aesar nickel sheet	https://www.fishersci.com/shop/products/nickel-foil/AA43098
Busbars	Copper bar stock	~3–5 kg	$100–$300	McMaster copper bar	https://www.mcmaster.com/copper-bars/
Electrolyte	Potassium hydroxide (KOH), 25–30 wt%	~100–150 L solution	$200–$500	Lab Alley KOH	https://www.laballey.com/products/potassium-hydroxide-koh
Anode Catalyst Bath Chemical	Nickel sulfate (NiSO₄)	~1–2 kg	$50–$200	Sigma-Aldrich	https://www.sigmaaldrich.com/US/en/product/aldrich/656895
Anode Catalyst Bath Chemical	Ferrous sulfate (FeSO₄)	~1 kg	$20–$80	Fisher Scientific	https://www.fishersci.com/shop/products/ferrous-sulfate-heptahydrate
Anode Catalyst Bath Chemical	Boric acid (H₃BO₃)	~1 kg	$10–$40	Sigma-Aldrich	https://www.sigmaaldrich.com/US/en/product/sial/695092