This paper details the process of designing, analysing, manufacturing, and testing an integrated solid-state hydrogen storage system. Analysis is performed to optimise flow distribution and pressure drop through the channels, and experimental investigations compare the effects of profile shape on the overall power output from the fuel cell. The storing of hydrogen is given much attention in the selection of a storage medium, and the effect of a cooling system to reduce the recharging time of the hydrogen storage vessel. The PTFE seal performed excellently, holding pressure over 60 bar, despite requiring changing each time the cell is opened. The assembly of the vessel was simple and straightforward, and there was no indication of pressure damage owing to the FEA analysis that was performed. The cooling chamber, although producing minor leaks due to design oversight, increased performance dramatically, showing a reduction in internal powder temperature from 130°C, down to 25°C during the absorption process, as well as reducing the absorption time down from 30 minutes to just over 5 minutes. The novel idea of implanting a sheathed thermocouple into the centre of the hydride powder proved to be highly valuable asset and provided important information, especially during desorption where the outside container could be heating up, while the inner powder is still cooling down, data that have not been seen before.
