Modular roll-to-roll system and method for synthesis, fabrication, characterization, and testing of catalysts and catalytic coatings

Abstract

The present invention relates to the field of high-throughput material processing and testing, particularly to modular roll-to-roll systems designed for the continuous and autonomous synthesis, characterization, and testing of catalysts and catalytic coatings.

Description

[0001] P7516PC00

[0002] 1

[0003] Modular roll-to-roll system and method for synthesis, fabrication, characterization, and testing of catalysts and catalytic coatings

[0004] The present invention relates to the field of high-throughput material processing and testing, particularly to modular roll-to-roll systems designed for the continuous and autonomous synthesis, characterization, and testing of catalysts and catalytic coatings.

[0005] Background

[0006] Catalysts and catalytic coatings play a central role in a wide range of industrial applications, including energy production, environmental remediation, and chemical synthesis. The discovery and optimization of these materials typically require iterative experimentation to evaluate various compositions, morphologies, and processing conditions. Conventional methodologies for catalyst and coating development often rely on batch processing and manual testing, which are labor-intensive, time-consuming, and lack the scalability to address the increasing demand for efficient and sustainable materials. The production of ammonia and related discoveries for catalysts for ammonia production serve as examples of how extensive and manual experimentation in catalyst discovery was carried out historically.

[0007] Existing technologies, such as standalone systems for synthesis and testing, often operate in isolation, requiring extensive sample preparation and transfer between steps. This disjointed approach introduces inefficiencies, including potential contamination, inconsistent sample handling, and delays between synthesis and characterization. Moreover, these systems are frequently limited in their ability to handle continuous substrates, such as wires or films, which are increasingly used in applications.

[0008] Another limitation of current approaches is their inability to support high-throughput experimentation effectively. While high-throughput screening is recognized as a powerful tool for accelerating materials discovery, many existing systems are not equipped to perform seamless, automated processing of substrates. This restricts their utility in optimizing catalysts and coatings across a wide parameter space.

[0009] Furthermore, the lack of modularity in traditional systems reduces their adaptability to new materials or testing methods, making it difficult to meet evolving research and industrial needs.P7516PC00

[0010] 2

[0011] It is an objective of the present disclosure to provide a system and method that address the inefficiencies and limitations of the current state of the art. The present disclosure aims to improve the scalability, flexibility, and reliability of catalyst and catalytic coating development while ensuring compatibility with various sample types and processing requirements.

[0012] Summary

[0013] The present disclosure relates to a modular roll-to-roll system for high-throughput screening of catalysts and / or catalytic coatings, preferably a modular roll-to-roll system for high-throughput fabrication, characterization, and / or testing of catalysts and / or catalytic coatings. The system may be configured to transport an elongated continuous flexible substrate, such as a wire, film or foam, through a plurality of configurable stations, and the elongated continuous flexible substrate may be configured to carry a plurality of sequential samples through the system for sequential screening of the sequential samples.

[0014] In a preferred embodiment the modular roll-to-roll system comprises at least one configurable cleaning station configured to initially clean the substrate as it passes through said at least one configurable cleaning station, at least one configurable synthesis station located downstream of the at least one configurable cleaning station and configured to perform a sequence of synthesis operations to create sequential samples on the substrate as the substrate passes through said at least one configurable synthesis station, said substrate being a clean substrate received from the at least one configurable cleaning station, and at least one configurable inline testing station located downstream of the at least one configurable synthesis station and configured to sequentially test the quality of and / or characterize the sequential samples as the substrate passes through said testing station, for example by electrochemically characterizing catalytic activity of the samples.

[0015] The present disclosure brings roll-to-roll manufacturing into catalyst science. The purpose of the modular roll-to-roll system is to solve at least three central issues: automatize the entire workflow (comprised by cleaning, synthesis, and testing), significantly enhance accuracy, reliability, and quantity of data, and provide flexibility byP7516PC00

[0016] 3

[0017] the modularity and configurability of the various stations as well as having the possibility of adding further stations.

[0018] The system enables a continuous and autonomous workflow by integrating cleaning, synthesis, and testing stations into a unified roll-to-roll process. A substrate is allowed to pass through configurable stations in a controlled manner, facilitating high-throughput experimentation and ensuring that multiple samples can be prepared, processed, and analyzed efficiently without manual intervention. The modularity of the system allows it to accommodate different synthesis techniques and testing methodologies, providing flexibility for various catalyst and coating applications.

[0019] The system may preferably comprise a liquid dispensing system to regulate and control the flow of liquids and chemical solutions to one or more of the configurable stations. The system may comprise a potentiostat to regulate the potential difference between a working electrode and a reference electrode while measuring the resulting current related to an electrochemical operation, such as within a configurable synthesis and / or testing station. One or more computationally units, such as microcontrollers may be part of the system. The system may comprise one or more microcontrollers to facilitate real-time control, integration, and coordination of the system’s constituent units.

[0020] The system may be configured to operate with different types of elongated continuous flexible substrates, such as wires, or dense or porous films, making the system adaptable to a wide range of material processing needs. The synthesis station may support multiple synthesis techniques, such as electrodeposition, chemical coating, metallic leaching, and alloying, enabling the fabrication of diverse compositions, including those suitable for use as catalysts. The testing station may include electrochemical and spectroscopic characterization techniques, facilitating inline quality assessment and performance evaluation of the synthesized materials.

[0021] The present disclosure also relates to a method for high-throughput fabrication, characterization, and testing of catalysts and / or catalytic coatings, comprising the steps of providing a modular roll-to-roll system comprising at least one configurable cleaning station, at least one configurable synthesis station, and at least one configurable inline testing station, providing an elongated continuous flexible substrate, such as a wire, film, or foam, to the system, said substrate configured to carry a plurality of sequentialP7516PC00

[0022] 4

[0023] samples through the system, and autonomously passing said substrate through the configurable stations of the modular roll-to-roll system to perform high-throughput fabrication, characterization, and testing of catalysts and / or catalytic coatings.

[0024] The method enables efficient screening and optimization of catalytic materials by automating the fabrication and analysis process. The roll-to-roll configuration ensures seamless sample handling and reproducibility, reducing variability and improving consistency in catalyst and coating development. The autonomous operation enhances scalability and accelerates material discovery by facilitating parallel or iterative testing within a controlled environment.

[0025] Brief description of drawings

[0026] Various embodiments are described hereinafter with reference to the drawings. The drawings are examples of embodiments and are intended to illustrate some of the features of the presently disclosed modular roll-to-roll system and method for synthesis, fabrication, characterization, and testing of catalysts and catalytic coatings.

[0027] FIG. 1 shows a schematic drawing of a modular roll-to-roll configured to transport an elongated continuous flexible substrate through a plurality of configurable stations, the system comprising an input roller configured to deliver an elongated continuous flexible substrate, a configurable cleaning station, a configurable synthesis station downstream of the configurable cleaning station, a configurable inline testing station downstream of the configurable synthesis station, and an output roller configured to collect a postprocessed elongated continuous flexible substrate.

[0028] FIG. 2 shows an embodiment of the modular roll-to-roll system of the present disclosure, the modular roll-to-roll system comprising an input roller, two configurable cleaning stations, one configurable synthesis station, one configurable inline testing station, an output roller, a plurality of support arms, and a liquid dispensing system.

[0029] FIG. 3 shows an embodiment of the output roller of the present disclosure, the output roller comprising a cylindrical section configured to wind the elongated continuous flexible substrate, a stabilizing rod, a stepper motor, and a support platform.P7516PC00

[0030] 5

[0031] FIG. 4 shows a schematic representation of an automated catalyst synthesis and testing platform configured according to the principles of the modular roll-to-roll system of the present disclosure, illustrating transport of an elongated continuous substrate through cleaning, synthesis, and electrochemical testing stations, together with associated liquid dispensing and electrochemical measurement components.

[0032] FIGS. 5A-5B illustrate electrochemical testing results obtained using the modular roll-to-roll system of the present disclosure, wherein FIG. 5A shows cyclic voltammetry measurements of a catalyst sample during an accelerated electrochemical stress test, and FIG. 5B shows the evolution of the overpotential at a set current density, as derived from the cyclic voltammetry scans.

[0033] Detailed description

[0034] Definitions

[0035] “Modular roll-to-roll system’’-. A system configured to transport a flexible substrate through a sequence of processing stations in a controlled, continuous, and automated manner. The system can be given a modular architecture, in which individual processing stations, such as cleaning stations, synthesis stations, and inline testing stations, are independently configurable, replaceable, and / or reconfigurable based on specific processing requirements. This modularity allows for flexibility in system setup, enabling users to customize the system for different applications, synthesis methods, testing techniques, and substrate types, without requiring extensive redesign or reconfiguration of the entire system. The system may operate without discrete handling steps, and may employ a continuous movement mechanism, such as by using a set of spools, mandrels, or reels to transport and wind an elongated flexible substrate, to process sequential samples and / or compositions positioned sequentially along the length of the substrate. The modularity allows customization based on processing requirements, supporting a wide range of materials, deposition methods, analytical techniques, and application-specific workflows. The operation of the system may be controlled by one or more computational units, such as one or more microcontrollers. A microcontroller may enhance the system’s automation, precision, and adaptability by real-time control, integration, and coordination of the system’s constituent units.

[0036] “Configurable cleaning station’’ A modular processing unit operable to remove contaminants, residues, or undesired surface layers from a substrate or sample beforeP7516PC00

[0037] 6

[0038] or after subsequent processing steps. The cleaning station may be adapted to perform one or more cleaning operations, comprising chemical cleaning, electrochemical cleaning, solvent-based cleaning, gas-phase cleaning, ultrasonic cleaning, or mechanical cleaning. The station may be reconfigurable to accommodate different cleaning methods, sample materials, or process requirements, either manually or through automated control. The term "configurable cleaning station" should be interpreted broadly to encompass not only cleaning processes but also various preparatory steps that condition the elongated continuous flexible substrate prior to synthesis, or characterization, or testing. These preparatory steps may comprise surface activation, etching, degreasing, plasma treatment, drying, or chemical functionalization, depending on the specific requirements of the downstream processes. Non-limiting examples may include one or more sequential configurable cleaning stations for the purpose of removing a passivating oxide layer from a flexible metal substrate by reacting the passivating oxide layer with a suitable acid or base. A configurable cleaning station may comprise heating elements to control the temperature of processing solutions or accelerated curing. Additionally, the station may comprise stirring elements, such as magnetic or mechanical agitators, to ensure uniform mixing of solutions. These elements can be integrated based on process requirements to optimize performance.

[0039] “Configurable synthesis station’’-. A modular processing unit adapted to perform one or more synthesis operations on a sample or substrate as it passes through the system. The synthesis station may be configured for various deposition, coating, or material modification techniques, comprising electrodeposition, chemical coating, metallic leaching, and alloying. The configurable synthesis station may support different synthesis methods such as Direct Current (DC) electrodeposition, pulse electrodeposition, electroless deposition, chemical vapor deposition, physical vapor deposition, sol-gel coating, spray pyrolysis, anodization, or plasma-assisted processes. The station may be reconfigurable to accommodate different synthesis techniques, materials, or process parameters, either manually or through automated control. A configurable synthesis station may comprise heating elements to control the temperature of processing solutions, facilitating reactions such as chemical deposition, thermal activation, or accelerated curing. Additionally, the station may comprise stirring elements, such as magnetic or mechanical agitators, to ensure uniform mixing of solutions, enhancing reaction consistency and coating homogeneity. These elementsP7516PC00

[0040] 7

[0041] can be integrated based on process requirements to optimize material synthesis and performance. In that regard the at least one configurable synthesis station can be seen as enabling fabrication of diverse compositions, including those suitable for use as catalysts and catalyst coating.

[0042] “Configurable inline testing station’’-. A modular processing unit operable to perform quality assessment, and / or characterization, and / or performance evaluation of a sample or substrate as it passes through the system. The testing station may be configured for various types of measurements, comprising electrochemical testing, spectroscopic analysis, structural characterization, and mechanical property assessment. Electrochemical testing may include techniques such as cyclic voltammetry, electrochemical impedance spectroscopy, chronoamperometry, and corrosion testing, while characterization methods may involve various X-ray diffraction (XRD) techniques, infrared (IR) spectroscopy, ultraviolet-visible (LIV-VIS) spectroscopy, or Raman spectroscopy. The testing station may further support post-processing evaluation, such as tensile testing, adhesion testing, surface roughness analysis, or thermal stability assessment. The station may be reconfigurable to accommodate different testing techniques, materials, or process parameters, either manually or through automated control, enabling adaptability for high-throughput screening and quality assurance of catalysts and catalytic coatings. A configurable inline testing station may comprise heating elements to control the temperature of processing solutions, facilitating reactions, thermal activation, or accelerate processes.

[0043] Additionally, the station may comprise stirring elements, such as magnetic or mechanical agitators, to ensure uniform mixing and / or enhance reaction consistency. These elements can be integrated based on process requirements to optimize performance. Testing in a configurable inline testing station should be interpreted broadly and may comprise characterization, such as electrochemical analysis, spectroscopic evaluation, mechanical property assessment, surface morphology inspection, conductivity measurements, and other analytical techniques to assess material composition, structure, and performance.

[0044] “Elongated continuous flexible substrate’’-. A substrate that extends in a continuous manner along a defined length and is configured to be transported through the modular roll-to-roll system for sequential processing. The substrate serves as a carrier for sequential samples, either by supporting material deposited or modified duringP7516PC00

[0045] 8

[0046] synthesis operations or by inherently comprising the sample material itself. The elongated continuous flexible substrate may take various forms, comprising a wire, a dense or porous film, such as a foil, a foam, a mesh, or a sinter, and the elongated continuous flexible substrate may be metallic, non-metallic, composite, or otherwise structured to accommodate high-throughput screening of catalysts and / or catalytic coatings. The substrate may further be adapted to support, attract, and facilitate the attachment of particulate matter, such as nanoparticles, during a coating process, for example through electrostatic interactions, chemical bonding, or physical adhesion.

[0047] “Potentiostat"'. An electronic control device configured to regulate the potential difference between a working electrode and a reference electrode while measuring the resulting current in an electrochemical system. The potentiostat is operable to control at least two working electrodes, such as within the configurable testing station, enabling electrochemical testing such as cyclic voltammetry, electrochemical impedance spectroscopy, chronoamperometry, chronopotentiometry, Tafel analysis, and potentiostatic or galvanostatic electrochemical deposition. The potentiostat may be adapted for single or multi-electrode configurations and may facilitate automated or real-time analysis of electrochemical properties of catalysts and catalytic coatings as part of a high-throughput screening process. In some embodiments, the elongated continuous flexible substrate may function as the working electrode in an electrochemical system, where the potentiostat applies a potential and measures the resulting current on the substrate during testing or deposition processes. In some embodiments the at least one configurable inline testing station comprises a potentiostat configured to control a potential between a working electrode and a reference electrode while measuring current.

[0048] “Liquid dispensing system"'. A system configured to regulate the controlled delivery, flow, and management of liquids, such as to and from configurable stations of a modular roll-to-roll system. The liquid dispensing system is operable to supply and collect liquids to and from one or more configurable stations, such as cleaning, synthesis, and / or testing stations, to facilitate various processes such as surface preparation, deposition, chemical reactions, or analytical testing. The system may accommodate a range of liquids, comprising one or more of deionized water, acidic solutions, alkaline solutions, metal-ion solutions, electrolytes, catalyst precursors, organic coating solutions, indicator solutions (such as pH, redox, or electrochemicalP7516PC00

[0049] 9

[0050] indicators), and solvent mixtures. The liquid dispensing system may comprise pumps, valves, reservoirs, conduits, and flow controllers, and may be designed for automated or programmable delivery to optimize high-throughput screening and process efficiency.

[0051] “Electrolyte”: A liquid or solution containing dissolved ions that may exemplary facilitate ionic conductivity and enable electrochemical reactions. An electrolyte may comprise metal ions (such as transition metal ions), non-metal ions, or a combination thereof, serving as a medium for charge transfer in processes such as electrodeposition, electrochemical testing, or catalytic reactions. Electrolytes may include aqueous or non-aqueous solutions, ionic liquids, or gel-based formulations.

[0052] Further details

[0053] Embodiments of the invention are associated with various advantages and / or technical effects.

[0054] The present disclosure in a preferred embodiment relates to a modular roll-to-roll system for high-throughput screening of catalysts and / or catalytic coatings, the system configured to transport an elongated continuous flexible substrate through a plurality of configurable stations, the elongated continuous flexible substrate configured to carry a plurality of sequential samples through the system for sequential screening of the sequential samples, the system comprising: at least one configurable cleaning station configured to initially clean the substrate as it passes through said at least one configurable cleaning station; at least one configurable synthesis station located downstream of the at least one configurable cleaning station and configured to perform a sequence of synthesis operations to create sequential samples on the substrate as the substrate passes through said at least one configurable synthesis station, said substrate being a clean substrate received from the at least one configurable cleaning station; and at least one configurable inline testing station located downstream of the at least one configurable synthesis station and configured to sequentially test the quality of and / or characterize the sequential samples as the substrate passes through said testing station.

[0055] The modular roll-to-roll system enables an automated and continuous workflow for pretreatment, fabrication, characterization, testing, and optimization of catalysts andP7516PC00

[0056] 10

[0057] catalytic coatings, all within a single integrated process. The present disclosure eliminates the need for manual intervention and discrete processing steps, and as such the system significantly reduces time and cost while improving reproducibility and consistency. The ability to conduct sequential processing on the same elongated continuous flexible substrate ensures that each sample experiences uniform treatment, reducing variability associated with separate batch-based approaches. This high-throughput capability accelerates catalyst discovery and optimization by streamlining material synthesis and analysis within a single platform.

[0058] The system is designed with a high degree of modularity, allowing for flexible and adjustable configurations tailored to different processing requirements. The selection of support materials, pre-treatment methods, fabrication techniques, characterization tools, and testing protocols can be customized based on the specific needs of the user. The configurable stations can accommodate a wide range of synthesis methods, such as electrodeposition and chemical coating, as well as various downstream inline testing stations, comprising electrochemical and spectroscopic analysis. This adaptability ensures that the system remains relevant for evolving applications in both research and industry, providing a scalable and versatile solution for catalyst and coating development.

[0059] The present disclosure offers a modular and flexible architecture that streamlines and automatizes at least three procedural steps (cleaning / preparation, synthesis operations, and testing) that have been traditionally treated separately. Unlike conventional systems that rely on robotic arms or linear actuators to transport or manipulate sequential samples, the present invention achieves fully autonomous operation without the need for complex moving parts. The absence of such mechanical components enhances system reliability and operational safety while reducing maintenance requirements and overall cost. By exploiting inherent movement of the roll-to-roll mechanism, the system maintains precise control over sample transport while eliminating sources of mechanical failure.

[0060] In one embodiment of the present disclosure, the system is configured to operate with the elongated continuous flexible substrate being a wire. The system may enable a continuous and flexible processing workflow, with a wire-shaped substrate providing advantages in terms of mechanical stability, handling, and surface uniformity, making itP7516PC00

[0061] 11

[0062] suitable for roll-to-roll processing. The wire may be transported through the system while maintaining tension, at least in some sections of the wire, ensuring controlled exposure to the various configurable stations for cleaning, synthesis, and testing. The use of a wire substrate allows for uniform deposition of catalyst materials and coatings along its length, facilitating high-throughput screening with minimal material waste.

[0063] The system may accommodate wires of different diameters, compositions, and surface properties, depending on the specific processing requirements. In one or more embodiments of the present disclosure, the flexible substrate or wire may be characterized by a diameter in the range of 0.01 mm to 5 mm, such as 0.01 mm to 0.05 mm, such as 0.05 mm to 0.10 mm, such as 0.10 mm to 0.25 mm, such as 0.25 mm to 0.50 mm, such as 0.50 mm to 1.0 mm, such as 1.0 mm to 2.0 mm, such as 2.0 mm to 3.0 mm, such as 3.0 mm to 4.0 mm, such as 4.0 mm to 5.0 mm. The wire may serve as a support for catalyst materials deposited during synthesis or may itself be a catalytic material subject to modification or enhancement through one or more synthesis operations. The continuous nature of the wire enables uninterrupted sample processing, reducing variability associated with discrete sample handling and improving reproducibility across multiple sequential samples. The roll-to-roll transport mechanism may further ensure precise control over the movement of the wire, optimizing exposure times and ensuring consistent processing conditions.

[0064] This embodiment may be suitable for a range of use cases, such as in the development of catalytic coatings for electrochemical applications, fuel cells, batteries, and industrial catalytic processes.

[0065] In one embodiment of the present disclosure, the system is further configured to operate with the wire being a metallic wire composed of a metal or a metal alloy, such as a metallic wire comprising at least one of platinum, gold, silver, copper, nickel, titanium, tungsten, aluminium, or stainless steel. Metallic wires provide advantageous electrical, thermal, and mechanical properties that enhance their suitability for various catalytic and coating applications. The conductivity of metallic wires makes them relevant for electrochemical applications, where they may serve as electrodes or conductive supports for catalyst materials. Their mechanical strength and durability further ensure reliable transport through the system while maintaining consistent tension and stability during processing.P7516PC00

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[0067] The system may accommodate metallic wires of various geometric specifications and alloy compositions, allowing for flexibility in synthesis and testing procedures. The selection of metal may be based on specific catalytic properties, corrosion resistance, or compatibility with synthesis techniques such as electrodeposition or chemical vapor deposition. Platinum, gold, and silver wires, for example, are commonly used in electrochemical and sensor applications due to their excellent conductivity and chemical stability. Nickel and stainless steel wires may provide cost-effective alternatives with good mechanical strength and corrosion resistance, making them suitable for large-scale catalyst screening. Titanium and tungsten wires may be selected for high-temperature or specialized catalytic applications requiring enhanced durability. Aluminium, known for its lightweight nature and corrosion resistance, may serve as a substrate for coatings or functionalized surfaces in energy and structural applications.

[0068] In one embodiment of the present disclosure, the system is further configured to operate with the wire being a non-metallic wire, such as a non-metallic wire comprising carbon fibres, carbon nanotubes, or graphite. Non-metallic wires provide distinct advantages in catalytic applications, particularly in fields where lightweight materials, high surface area, and chemical stability are desirable. Carbon-based wires, for example, offer excellent electrical conductivity, mechanical flexibility, and resistance to corrosion, making them well-suited for electrochemical and catalytic coating applications.

[0069] Carbon fibre wires, for example, provide a mechanically robust yet lightweight substrate, making them suitable for structural reinforcement applications or hybrid composite coatings. Carbon nanotube wires offer high conductivity and nanoscale porosity, making them suitable as catalyst supports or active electrode materials in energy storage and conversion applications. Graphite wires, known for their stability and lubricating properties, may be used in specialized coatings or as conductive substrates for electrodeposition processes. The system may be configured to handle these materials with precision, ensuring uniform deposition and consistent characterization of catalytic properties.P7516PC00

[0070] 13

[0071] In one embodiment of the present disclosure, the system is configured to operate with the elongated continuous flexible substrate being a dense or porous film, such as a foam, a mesh, or a sinter. The use of foams, meshes, or sinters as substrates enables a wider range of material processing applications by providing alternative structural and chemical properties compared to wire-based substrates. Films offer a flexible, planar surface that can facilitate uniform coating deposition, patterning, or functionalization, making them particularly suitable forthin-film catalysts, membrane electrodes, and protective coatings. Foams, on the other hand, provide a porous, three-dimensional structure with a large surface area, which can enhance catalytic activity by increasing the number of active sites available for reaction. Dense films provide a smooth and continuous surface suitable for uniform coatings, while porous films, foams, meshes, and sintered materials offer high surface area and permeability, which can enhance catalytic activity and material interactions in electrochemical and gas-phase applications.

[0072] The system may accommodate films and foams composed of various materials, such as metallic, polymeric, ceramic, or carbon-based compositions. Foams, such as metal or carbon foams, provide an interconnected porous network that facilitates mass transport and may serve as high-surface-area supports for catalysts used in energy storage, electrolysis, or filtration applications. Meshes, which consist of woven or perforated structures, allow for controlled diffusion of reactants and can improve adhesion of functional coatings. Sintered materials, formed by compacting and heat-treating powders without full melting, provide mechanically robust and highly porous substrates that are often used in catalyst supports, electrodes, and filtration membranes.

[0073] In one embodiment of the present disclosure, the system is configured to operate with the sample comprise particles, such as nanoparticles. The ability to process particulate sequential samples enables the deposition, dispersion, or integration of nanoscale materials onto an elongated continuous flexible substrate, expanding the system's applicability to advanced catalytic coatings and functional material synthesis.

[0074] Nanoparticles may be applied through various techniques, such as electrochemical deposition, spray coating, dip coating, or layer-by-layer assembly, depending on the desired material properties and interaction with the substrate. The system may beP7516PC00

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[0076] configured to ensure uniform distribution of nanoparticles across the surface of the substrate, enhancing catalytic efficiency and material performance.

[0077] The system may accommodate a wide range of particle compositions, including metallic, metal oxide, carbon-based, or composite nanoparticles, tailored to specific catalytic or functional applications. For example, noble metal nanoparticles such as platinum or gold may be incorporated into coatings for electrocatalytic applications, while metal oxide nanoparticles may enhance catalytic activity in redox reactions. Carbon-based nanoparticles, such as graphene or carbon nanotubes, may be used to improve conductivity and mechanical strength in composite coatings. The system may be further adapted to facilitate in-situ synthesis or functionalization of nanoparticles directly on the substrate, enabling high-throughput screening and optimization of nanoparticle-based catalysts and coatings.

[0078] The presently disclosed system can handle diverse nanoparticle composition and deposition techniques and is not limited to, for example, core-shell catalysts. The presently disclosed system’s architecture and modularity can facilitate in-situ synthesis or functionalization of nanoparticles directly on the substrate, which in turn enables high-throughput screening and optimization of nanoparticle-based catalysts and coatings.

[0079] In one embodiment of the present disclosure, the at least one of the configurable inline testing stations is configured for electrochemical testing, such as cyclic voltammetry, linear sweep voltammetry, electrochemical impedance spectroscopy, chronoamperometry, chronopotentiometry, Tafel analysis, and / or corrosion testing. Electrochemical testing provides performance data on catalysts and coatings by assessing their properties such as conductivity, reaction kinetics, stability, and / or overall electrochemical behavior. This embodiment thus enables real-time characterization of processed samples without requiring separate, off-line analysis, thereby improving efficiency and reproducibility in high-throughput screening.

[0080] The inline testing station may be configured to assess various electrochemical properties depending on the material and application. Cyclic voltammetry and linear sweep voltammetry may be used to investigate redox behavior and catalytic activity, while electrochemical impedance spectroscopy provides insights into charge transferP7516PC00

[0081] 15

[0082] resistance and conductivity. Chronoamperometry and chronopotentiometry allow for the evaluation of material stability and long-term performance under controlled potential or current conditions. Tafel analysis may be used to determine reaction kinetics and corrosion rates, while corrosion testing can assess the durability and protective qualities of coatings under different environmental conditions.

[0083] In one embodiment of the present disclosure, at least one of the configurable inline testing stations is configured for performing inline characterization, such as with X-ray diffraction (XRD), infrared (IR) spectroscopy, ultraviolet-visible (LIV-VIS) spectroscopy, and / or Raman spectroscopy. Inline characterization enables real-time assessment of structural, chemical, and optical properties of the processed samples as they pass through the roll-to-roll system, eliminating the need for separate offline analysis and enhancing the efficiency of high-throughput screening.

[0084] The configurable inline testing station may be configured to analyze different material properties depending on the technique used. X-ray diffraction (XRD) may be used to determine crystallinity, phase composition, and lattice structure, providing insights into the structural properties of coatings and catalysts. Infrared (IR) spectroscopy can be employed to identify functional groups and chemical bonds, enabling the detection of surface modifications or molecular interactions in deposited films. Ultraviolet-visible (UV-VIS) spectroscopy may be used to measure optical absorbance and electronic transitions, which may be useful for assessing thin films and optically active materials. Raman spectroscopy provides vibrational fingerprinting for molecular and structural characterization, allowing for detailed chemical analysis of coatings and catalyst compositions.

[0085] In one embodiment of the present disclosure, the at least one synthesis operation is one or more selected from electrodeposition, chemical coating, metallic leaching, and / or alloying. The system may be configured to perform these synthesis operations in a continuous and controlled manner as the elongated continuous flexible substrate progresses through the roll-to-roll process. By enabling diverse synthesis techniques within a modular and automated framework, the system supports high-throughput fabrication of functional materials, including catalysts, and coatings for various applications.P7516PC00

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[0087] Electrodeposition may be used to deposit metals, alloys, or composite coatings onto the substrate through electrochemical processes, allowing for precise control over thickness, morphology, and composition. Chemical coating methods, such as sol-gel deposition, vapor-phase techniques, or solution-based coatings, enable the formation of protective, catalytic, or functional layers. Metallic leaching may involve selective removal of certain elements from an alloyed or coated substrate to create porous or high-surface-area structures, which may be beneficial for electrocatalysts and functional coatings. Alloying processes may include the formation of mixed-metal or intermetallic compositions, either through co-deposition, diffusion, or controlled thermal treatment.

[0088] In one embodiment of the present disclosure, the at least one configurable synthesis station is configured for electrodeposition techniques, such as potentiostatic or galvanostatic electrochemical deposition, direct current electrodeposition, pulse electrodeposition, reverse pulse electrodeposition, electroless deposition, template-assisted electrodeposition, and / or high-voltage electrodeposition. The system may facilitate precise and controlled deposition of metallic, alloy, or composite coatings onto an elongated continuous flexible substrate, enabling high-throughput synthesis of functional materials such as for catalytic, protective, or electrochemical applications.

[0089] Potentiostatic or galvanostatic electrochemical deposition allows for controlled deposition by maintaining a constant potential or current, respectively, ensuring uniformity in film thickness and composition. Direct current electrodeposition provides a continuous deposition process, while pulse and reverse pulse electrodeposition introduce periodic variations in applied current or voltage to improve film quality, control grain size, or enhance adhesion properties. Electroless deposition enables the formation of coatings without an external electrical bias by utilizing chemical reduction reactions. Template-assisted electrodeposition may be employed to create structured or nanoporous coatings by utilizing predefined templates to guide material growth. High-voltage electrodeposition can facilitate rapid deposition or enhanced film adhesion under elevated electrical fields.

[0090] In one embodiment of the present disclosure, the at least one configurable synthesis station is configured for performing chemical and electrochemical coating, such as chemical vapor deposition, physical vapor deposition, sol-gel coating, spray pyrolysis,P7516PC00

[0091] 17

[0092] spin coating, dip coating, spray coating, atomic layer deposition, and / or layer-by-layer deposition. These coating techniques enable the deposition of thin films, functional layers, or catalytic coatings onto an elongated continuous flexible substrate, providing a versatile and scalable approach for material synthesis in high-throughput applications.

[0093] Chemical vapor deposition (CVD) and physical vapor deposition (PVD) may be used to form uniform and adherent coatings by vapor-phase deposition of solid materials onto the substrate, making them useful for catalytic or protective coatings. Sol-gel coating enables the deposition of metal oxide or hybrid coatings from a liquid precursor, allowing for precise control over composition and porosity. Spray pyrolysis facilitates the formation of coatings by thermally decomposing sprayed precursor solutions, while spin coating and dip coating offer controlled film thickness through centrifugal or immersion-based deposition methods. Spray coating provides a scalable approach for uniform and rapid material deposition across large surface areas. Atomic layer deposition (ALD) allows for atomic-scale precision in thin film growth, ensuring uniform coverage even on complex or high-aspect-ratio surfaces. Layer-by-layer deposition enables sequential build-up of multi-layered films with tailored properties.

[0094] In one embodiment of the present disclosure, the at least one configurable synthesis station is configured for specialized electrodeposition and coating techniques, such as hydrothermal electrodeposition, anodization, plasma electrolytic oxidation, electrophoretic deposition, brush plating, magnetron-assisted coating, and / or plasma-enhanced electrodeposition. These techniques provide enhanced control over the composition, structure, and functional properties of coatings, enabling the development of advanced catalytic, protective, and electrochemical materials.

[0095] Hydrothermal electrodeposition involves the electrochemical growth of coatings under elevated temperature and pressure, facilitating the formation of highly crystalline and adherent films. Anodization enables the controlled formation of oxide layers on a metal substrate, improving corrosion resistance and enhancing surface properties for catalytic or electrochemical applications. Plasma electrolytic oxidation (PEO) extends anodization by incorporating plasma discharges to create thicker and more complex oxide coatings with superior wear resistance and stability. Electrophoretic deposition (EPD) allows for the uniform deposition of charged particles onto a substrate, enabling the fabrication of composite coatings with tailored compositions. Brush plating providesP7516PC00

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[0097] a localized electrodeposition approach, allowing selective coating of specific regions of a substrate without immersing the entire material in an electrolyte bath. Magnetron-assisted coating employs sputtering techniques to deposit thin films under vacuum conditions, ensuring uniform and high-quality coatings with precise material control. Plasma-enhanced electrodeposition utilizes reactive plasma environments to modify deposition kinetics, improving coating adhesion and microstructural properties.

[0098] In one embodiment of the present disclosure, the system further comprises a postprocessing testing station, such as configured for tensile testing, flexural or bend testing, adhesion testing, hardness testing, impact resistance testing, thickness measurements, surface roughness testing, thermal testing, fatigue testing, conductivity testing, magnetic susceptibility testing, superconductivity testing, visual and optical inspection, load or compression testing, residual stress testing, and / or creep testing. The post-processing testing station enables detailed mechanical, thermal, electrical, and structural characterization of the processed samples, ensuring that they meet predefined quality and performance criteria for their intended applications.

[0099] In some embodiments, the post-processing testing station may be modular and / or configurable, providing flexibility in testing different material properties and adapting to various process requirements. A modular configuration allows the station to be reconfigured or replaced with different testing setups, enabling compatibility with multiple mechanical testing techniques.

[0100] Tensile testing, flexural testing, and load or compression testing assess the mechanical strength and deformation behavior of the substrate and coatings under applied forces. Adhesion testing evaluates the bonding strength of coatings to the substrate, ensuring durability and reliability in practical applications. Hardness testing and impact resistance testing determine the material’s resistance to surface deformation and sudden mechanical stresses. Thickness measurements and surface roughness testing ensure that coatings meet required dimensional and morphological specifications. Thermal testing may be used to evaluate heat resistance, thermal conductivity, or thermal expansion properties. Fatigue testing examines the durability of materials under cyclic loading, while residual stress testing and creep testing assess long-term mechanical stability. Electrical characterization, such as conductivity testing, magnetic susceptibility testing, and superconductivity testing (usually comprising measurementsP7516PC00

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[0102] of resistivity, response to external magnetic field, and heat capacity), provides insight into the functional properties of materials for applications in electronics, energy storage, and catalysis. Visual and optical inspection allows for defect detection and quality assurance in high-throughput screening.

[0103] In one embodiment of the present disclosure, the system further comprises an input roller configured to deliver an elongated continuous flexible substrate. The input roller serves as a support structure for holding and dispensing the substrate in a controlled manner as it progresses through the roll-to-roll system. By providing a stable and regulated feed mechanism, the input roller can ensure consistent tension, tracking, and alignment of the substrate, reducing disruptions and variations in processing. The configuration of the input roller may be adapted to accommodate different substrate types, including wires, films, and foams, allowing for seamless integration with the transport mechanism of the system.

[0104] The input roller may be configured to function passively or actively, depending on the processing requirements. In some embodiments, the input roller may comprise tension control mechanisms, such as adjustable friction elements, to regulate the feed rate and prevent substrate slippage or misalignment. In other embodiments, the input roller may be motorized to synchronize substrate movement with downstream processing stations, ensuring uniform exposure to cleaning, synthesis, and testing operations.

[0105] In one embodiment of the present disclosure, the system further comprises an output roller configured to collect a post-processed elongated continuous flexible substrate. The output roller provides a controlled means of winding and storing the substrate after the substrate has undergone processing within the system, ensuring that the processed material remains organized and protected from contamination or mechanical damage. By maintaining continuous and regulated collection, the output roller enables seamless operation of the roll-to-roll process, supporting high-throughput screening and fabrication of functional materials such as non-limiting catalysts and catalytic coatings.

[0106] The output roller may also facilitate a controlled and precise backtracking mechanism to correlate the quality or output of a testing station with a specific section of the elongated continuous substrate. For example, when using a substantially non-elasticP7516PC00

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[0108] substrate, such as a metallic wire, and maintaining fixed mechanical parameters for the output roller, including rotation speed and geometric dimensions (e.g., diameter in the case of an output roller with a cylindrical section), the system can establish a direct correspondence between the synthesis process parameters applied to a given substrate section and its downstream position on the output roller. This enables the roll-to-roll system to automatically track and associate specific synthesis conditions with the resulting test data, improving process monitoring and optimization.

[0109] In one or more embodiments of the present disclosure, the output roller may be configured to operate at a slow revolution speed of 0.005 Rounds Per Minute (RPM) to 5 RPM,, such as 0.005 RPM, such as 0.01 RPM, such as 0.1 RPM, such as 0.5 RPM, such as 1.0 RPM, such as 2.0 RPM, such as 3.0 RPM, such as 4.0 RPM, such as 5.0 RPM; or may be configured to operate at moderate speeds of 5 RPM to 20 RPM, such as 6.0 RPM, such as 8.0 RPM, such as 10 RPM, such as 12 RPM, such as 14 RPM, such as 16 RPM, such as 18 RPM, such as 20 RPM.

[0110] In one or more embodiments of the present disclosure, the typical transportation speed of the flexible substrate is configured to be in the range of 0.1 cm / min to 100 cm / min, such as 0.1 cm / min to 1 cm / min, such as 1 cm / min to 10 cm / min, such as 10 cm / min to 15 cm / min, such as 15 cm / min to 20 cm / min, such as 20 cm / min to 25 cm / min, such as 25 cm / min to 30 cm / min, such as 30 cm / min to 35 cm / min, such as 35 cm / min to 40 cm / min, such as 40 cm / min to 45 cm / min, such as 45 cm / min to 50 cm / min, such as 50 cm / min to 55 cm / min, such as 55 cm / min to 60 cm / min, such as 60 cm / min to 65 cm / min, such as 65 cm / min to 70 cm / min, such as 70 cm / min to 75 cm / min, such as 75 cm / min to 80 cm / min, such as 80 cm / min to 85 cm / min, such as 85 cm / min to 90 cm / min, such as 90 cm / min to 95 cm / min, such as 95 cm / min to 100 cm / min.

[0111] The output roller may be configured to function passively or actively, depending on the processing requirements. In some embodiments, the output roller may include tension control mechanisms to maintain uniform winding and prevent substrate deformation. In other embodiments, the output roller may be motorized, for example, powered by a stepper motor, to precisely coordinate substrate collection with the feed rate of the input roller and / or the output roller and the processing stations. The use of a stepper motor allows for controlled and incremental movement, ensuring smooth andP7516PC00

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[0113] synchronized operation while maintaining precise tension and alignment of the elongated continuous flexible substrate.

[0114] In one embodiment of the present disclosure, the input roller and / or the output roller comprise a cylindrical section, such as a spool, a mandrel, or a reel, configured to wind an elongated continuous flexible substrate such as a wire or a film. The cylindrical section provides a structured and stable surface for controlled winding and unwinding of the substrate, ensuring that the roll-to-roll system maintains consistent tension and alignment throughout the processing workflow. This configuration allows for efficient handling of flexible substrates while reducing the risk of mechanical deformation or misalignment that could impact subsequent processing steps.

[0115] The cylindrical section may be dimensioned and designed based on the material properties of the elongated continuous flexible substrate, ensuring compatibility with various substrate types and thicknesses. In some embodiments, the cylindrical section may feature a surface texture or tension-regulating elements to optimize the grip and stability of the wound substrate. This embodiment may incorporate spools, mandrels, or reels, which enables precise control over substrate feed and collection, facilitating smooth integration with the cleaning, synthesis, and testing stations.

[0116] In one embodiment of the present disclosure, the system further comprises a liquid dispensing system configured to control the delivery of liquids to the at least one configurable cleaning station, the at least one configurable synthesis station, and / or the at least one configurable inline testing station. The liquid dispensing system ensures precise and automated regulation of liquid flow throughout the roll-to-roll process, enhancing consistency, efficiency, and reproducibility across cleaning, synthesis, and testing operations.

[0117] The liquid dispensing system may be adapted to supply different types of liquids tailored to the requirements of each station. In the cleaning station, the liquid dispensing system may dispense solvents, detergents, acidic or alkaline solutions to remove contaminants and prepare the substrate surface. In the synthesis station, the liquid dispensing system may deliver electrolytes for electrodeposition, solutions for chemical coating, or reactive solutions for processes such as leaching or alloying. In the inline testing station, the liquid dispensing system may supply electrolyte solutionsP7516PC00

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[0119] for electrochemical testing, indicator solutions for spectroscopic analysis, or rinsing liquids for sample preparation before characterization.

[0120] The liquid dispensing system may be physically separated from the configurable stations of the roll-to-roll system while remaining fluidly connected via connecting tubes that transport the relevant liquids to designated processing areas. These tubes may be configured to deliver liquids with precise flow control to the configurable cleaning station, configurable synthesis station, and / or configurable inline testing station, ensuring accurate and efficient distribution. In some embodiments, the liquid dispensing system may include a plurality of liquid dispensers, each dedicated to handling specific types of liquids, such as acidic or alkaline solutions for cleaning, electrolyte solutions for electrodeposition, or indicator solutions for testing. The liquid dispensing system may incorporate pumps, valves, flow meters, and reservoirs to precisely regulate flow rates, dispensing volumes, and liquid composition. A physical separation while maintaining fluidic connectivity can facilitate minimizing contamination risks, optimize space utilization, and enhance process flexibility in high-throughput material screening and synthesis.

[0121] The liquid dispensing system may comprise a computational unit configured to automate the control and distribution of liquids to one or more stations within the roll-to-roll system. The computational unit may regulate liquid flow rates, dispense precise volumes, and adjust liquid composition based on predefined processing parameters or real-time feedback from sensors. The computational unit may be a microcontroller incorporating a processor, memory, and input / output peripherals on a single chip. The microcontroller may for example be used to regulate flow rates, control valves, and adjust liquid composition based on real-time feedback.

[0122] By integrating automated control, the system ensures consistent and reproducible liquid delivery, minimizing variability in cleaning, synthesis, and testing processes. In some embodiments, the computational unit may be programmed to dynamically modify dispensing parameters in response to changes in substrate properties, process conditions, or analytical measurements obtained from configurable inline testing stations. This automation enhances process efficiency, reduces human intervention, and supports high-throughput screening by optimizing liquid usage and maintaining precise process conditions throughout the roll-to-roll workflow.P7516PC00

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[0124] In one embodiment of the present disclosure, the liquid dispensing system is configured to deliver liquids to the at least one configurable cleaning stations, the liquid comprising deionized water, acidic solutions, metal-ion solutions, transition-metal ion solutions, alkaline solutions, detergent solutions, surfactant solutions, and / or solvent mixtures. The ability to dispense a range of cleaning liquids ensures that the cleaning station can effectively prepare the elongated continuous flexible substrate for subsequent synthesis and testing by removing contaminants, residues, or oxide layers.

[0125] The liquid dispensing system may be designed to regulate the flow, concentration, and application of cleaning liquids based on the substrate type and cleaning requirements. Deionized water may be used for rinsing and removing soluble contaminants, while acidic and alkaline solutions may facilitate etching, oxide removal, or surface activation. Metal-ion and transition-metal ion solutions may be applied to precondition the substrate for electrodeposition or catalytic activation. Detergent and surfactant solutions can assist in removing organic residues, greases, or particulates, ensuring a clean and uniform surface. Solvent mixtures may be employed for degreasing, removing polymeric residues, or preparing surfaces for chemical reactions.

[0126] In one embodiment of the present disclosure, the liquid dispensing system is configured to deliver liquids for the at least one configurable synthesis station, the liquid comprising electrolytes, precursors for chemical coatings, organic coating solutions, and / or catalyst precursors. The ability to precisely control the supply of these liquids enables the system to facilitate various synthesis processes, such as electrodeposition, chemical coating, and catalytic material deposition, ensuring reproducibility and efficiency in high-throughput material fabrication.

[0127] The liquid dispensing system may be configured to supply electrolytes for electrochemical deposition, allowing for controlled metal or composite film formation on the elongated continuous flexible substrate. Precursors for chemical coatings may include metal-organic solutions, sol-gel formulations, or reactive species used in chemical vapor deposition or solution-based deposition techniques. Organic coating solutions may be used for polymeric or hybrid coatings that provide protective, conductive, or functional properties. Catalyst precursors, including metal salts,P7516PC00

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[0129] nanoparticles, or molecular catalysts, may be dispensed in controlled concentrations to facilitate the formation of active catalytic layers.

[0130] In one embodiment of the present disclosure, the liquid dispensing system is configured to deliver liquids for the at least one configurable inline testing station, the liquid comprising electrochemical testing solutions, indicator solutions, and / or cleaning or rinsing solutions. The ability to precisely dispense these liquids ensures that the inline testing station can perform accurate and reproducible characterization of the synthesized or coated sequential samples while maintaining clean and controlled testing conditions.

[0131] The liquid dispensing system may supply electrochemical testing solutions, such as electrolytes, to facilitate techniques including cyclic voltammetry, electrochemical impedance spectroscopy, chronoamperometry, and corrosion testing. These solutions may include acidic, alkaline, or neutral electrolytes tailored to specific electrochemical analyses. Indicator solutions may be used for spectroscopic or colorimetric testing, enabling real-time chemical composition assessment or reaction monitoring. Cleaning and rinsing solutions, such as deionized water or solvent-based mixtures, may be dispensed to remove residues, contaminants, or excess reactants from the substrate before or after testing.

[0132] In one embodiment of the present disclosure, the system further comprises a control mechanism for controlling the at least two working electrodes of the at least one configurable inline testing station. The inclusion of such a control mechanism allows for precise regulation of electrochemical testing conditions, enabling accurate and reproducible evaluation of functional materials including catalysts and catalytic coatings. The system may be configured to independently or simultaneously control multiple working electrodes, facilitating comparative analysis of different samples or experimental conditions within a single testing sequence.

[0133] The control mechanism for controlling the working electrodes may include an electronic control unit capable of applying and regulating electrical potentials and currents across the electrodes. This allows for the execution of various electrochemical techniques, including cyclic voltammetry, electrochemical impedance spectroscopy, chronoamperometry, and chronopotentiometry.P7516PC00

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[0135] In one embodiment of the present disclosure, the control mechanism for controlling the at least two working electrodes is a potentiostat. A potentiostat is an electronic control device that regulates the potential difference between a working electrode and a reference electrode while measuring the resulting current. The potentiostat may serve to control at least one operation in the at least one configurable inline testing station, such as precise electrochemical characterization of functional materials including catalysts and catalytic coatings. This allows for controlled and reproducible testing conditions across multiple samples, which may enhance uniformity and accuracy in the post-processed samples.

[0136] The potentiostat may be configured to independently or simultaneously control multiple working electrodes, facilitating parallel testing of different compositions produced in the synthesis station, such as exemplary metal alloys, catalysts or coating formulations. This functionality allows for the execution of various electrochemical techniques, such as cyclic voltammetry, electrochemical impedance spectroscopy, chronoamperometry, and chronopotentiometry, to assess key performance parameters such as reaction kinetics, charge transfer resistance, and catalytic stability.

[0137] The potentiostat may be a commercially available potentiostat, such as a Squidstat Plus Potentiostat with an Electrochemical Impedance Spectroscopy (EIS) frequency range of 10 pHz to 2 MHz, a voltage scan range of -10 V to 10 V, and a current range of -1 A to 1A.

[0138] In one embodiment of the present disclosure, the system further comprises a backtracking device configured to monitor and correlate at least one synthesis operation with a position along an elongated continuous substrate. The backtracking device enables precise tracking of process parameters applied to specific sections of the substrate, ensuring that synthesis conditions, such as deposition parameters, reactant concentrations, or processing time, can be directly and unambiguously correlated with the properties and performance of the resulting material. This functionality enhances process control and facilitates systematic optimization of functional materials such as catalysts and catalytic coatings.P7516PC00

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[0140] The backtracking device may comprise a computational unit such as a microcontroller. The computational unit may be used to synchronize substrate position tracking with synthesis and testing operations.

[0141] The backtracking device may utilize various monitoring techniques, such as optical encoding, position tracking sensors, or integrated system logs, to record the substrate’s movement and its exposure to different synthesis operations. By maintaining a one-to-one correspondence between synthesis conditions and substrate position, the system allows for accurate downstream characterization and testing, ensuring that performance data obtained at the testing station can be directly linked to specific processing parameters. This capability improves reproducibility, enables targeted process refinements, and supports high-throughput material screening by providing traceable quality assessment throughout the roll-to-roll workflow.

[0142] The backtracking device may exploit the continuous and elongated nature of the substrate to accurately track its position during processing. For example, when the elongated continuous flexible substrate is a substantially non-elastic wire, the displacement of a specific location along the substrate can be determined based on the elapsed time and the transport speed. The transport speed may be regulated by controlling the rotational speed of a roller within the roll-to-roll system, which supports and transports the substrate. By maintaining a known correlation between substrate movement and processing time, the system can precisely identify the position of a given section relative to synthesis and testing operations, ensuring accurate process monitoring and data correlation.

[0143] In one embodiment of the present disclosure, the system further comprises at least one configurable drying and / or heating station. The drying and / or heating station allows for controlled thermal processing of the elongated continuous flexible substrate at various stages of the roll-to-roll workflow. The at least one station may be used to remove residual solvents, cure coatings, facilitate chemical reactions, or enhance the adhesion and stability of deposited catalyst materials. By integrating a configurable drying and / or heating station, the system enables precise temperature control to optimize material properties and processing conditions.P7516PC00

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[0145] The at least one drying and / or heating station may be configured to operate using different thermal techniques, including convective heating, infrared heating, resistive heating, or inductive heating, depending on the requirements of the synthesis and postprocessing steps. In some embodiments, the station may include adjustable temperature settings and heating durations to accommodate different substrate materials and coating compositions.

[0146] In a variation of this embodiment, the heating in the at least one configurable drying and / or heating station may take place under a controlled atmosphere to regulate the chemical environment during thermal processing. The controlled atmosphere may include inert gases, such as nitrogen or argon, to prevent oxidation, or reactive gases, such as hydrogen or ammonia, to facilitate reduction or specific surface modifications. In some embodiments, the station may operate under vacuum conditions to enhance drying efficiency or control phase transformations. This capability allows for precise thermal treatment tailored to the requirements of different catalyst materials, coatings, or functional surfaces, improving process consistency and material performance.

[0147] In one embodiment of the present disclosure, the system further comprises at least one configurable pretreatment station configured to prepare a part of the elongated continuous flexible substrate and / or samples prior to entering the at least one downstream configurable synthesis station. The pretreatment station enables controlled modification of the substrate surface or material properties, ensuring optimal conditions for subsequent synthesis operations such as electrodeposition, chemical coating, or alloying. By incorporating a dedicated pretreatment step, the system enhances process consistency, adhesion properties, and overall material performance.

[0148] In this embodiment the term “pretreatment” refers to a preparatory step that occurs upstream of the at least one synthesis station, where a synthesis operation — herein broadly referred to as “treatment” — is performed.

[0149] The configurable pretreatment station may be adapted to perform various processes depending on the requirements of the substrate and the intended synthesis technique. These processes may include chemical cleaning to remove contaminants or oxide layers, surface activation through plasma treatment or etching, mechanical polishing for improved coating uniformity, or electrochemical conditioning to modify surfaceP7516PC00

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[0151] properties. In some embodiments, the pretreatment station may also facilitate selective functionalization of the substrate by applying primer layers, adhesion promoters, or catalytic seed layers. In a variation of this embodiment, the at least one pretreatment station may be configured as at least one of a cleaning station or a washing station.

[0152] In one or more embodiments of the present disclosure, at least one of the configurable cleaning stations is configured for and provides a cleaning step comprising the use of an acid (acidic cleaning step) or base (alkaline cleaning step), preferably an aqueous acid or aqueous base, for the purpose of cleaning the substrate surface prior to the substrate entering the at least one configurable synthesis station. Cleaning may in one or more embodiments comprise a removal of passivating surface layers of the substrate, such as exemplary oxide and / or sulfide layers in the case of metallic substrates. In particular substrates comprising or consisting of the metals Al, Ni, Fe, Cr, and Ti are prone to formation of passivating oxide layers in ambient air at room temperature. The inclusion of an acidic or alkaline cleaning step as described herein can enhance the adhesion, uniformity, and overall quality of deposited coatings and / or alloys and / or functional materials obtained using the described system by ensuring a clean and well-prepared surface.

[0153] The acidic cleaning step may involve the application of aqueous solutions of acidic compounds providing a pH well below 7, preferably below 3, such as below 2, such as below 1, such as below 0. Non-limiting examples of acids used in the acidic cleaning step are hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, citric acid, or acetic acid. Preferably the acid is hydrochloric acid, sulfuric acid, or nitric acid.

[0154] The alkaline cleaning step may involve the application of aqueous solutions of alkaline compounds providing a pH well above 7, preferably above 10, such as above 12, such as above 14. Non-limiting examples of bases used in the alkaline cleaning step are alkali metal hydroxides (including sodium hydroxide, potassium hydroxide), magnesium hydroxide, calcium hydroxide, sodium carbonate, sodium bicarbonate, calcium carbonate, ammonia, or ammonium bicarbonate. Preferably the base is a metal hydroxide such as sodium hydroxide or potassium hydroxide.

[0155] In one or more embodiments of the present disclosure, at least one of the configurable cleaning stations is configured for and provides a cleaning step in the form of anP7516PC00

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[0157] organic cleaning step. The inclusion of an organic cleaning step allows for the removal of organic contaminants, such as oils, greases, polymers, or other organic residues, from the elongated continuous flexible substrate before it undergoes synthesis and / or testing. This process can enhance the adhesion, uniformity, and overall quality of deposited coatings and / or alloys and / or functional materials obtained using the described system by ensuring a clean and well-prepared surface.

[0158] The organic cleaning step may involve the application of organic solvents, surfactantbased cleaning solutions, or enzymatic treatments, depending on the nature of the contaminants and the substrate material. Solvents such as acetone, ethanol, isopropanol, or toluene may be used to dissolve and remove organic residues, while surfactant solutions can aid in the emulsification and removal of nonpolar contaminants. In some embodiments, ultrasonic agitation or heated organic cleaning solutions may be employed to enhance cleaning efficiency.

[0159] In one embodiment of the present disclosure, the system further comprises a plurality of support arms, wherein said support arms comprise at least one cylindrical section, such as a spool, mandrel, or reel, to support and transport the elongated continuous flexible substrate, wherein the plurality of support arms are configured to pass said substrate from one configurable station to a downstream configurable station. The support arms provide structural stability and guided movement for the substrate as it progresses through the system, ensuring controlled transport while maintaining proper alignment and tension. By integrating cylindrical sections, the support arms facilitate smooth handling of flexible substrates such as wires, films, or foams, reducing mechanical stress and preventing unintended deformation during processing.

[0160] The configuration of the support arms may be adapted to different processing requirements, allowing for customizable positioning and spacing to accommodate various substrate dimensions and material properties. In some embodiments, the support arms may be adjustable or modular, enabling optimization of substrate path geometry for specific synthesis or testing procedures. The support arms may further contribute to the system’s ability to regulate substrate feed rate and ensure consistent exposure to cleaning, synthesis, and testing stations. The feed rate may vary from support arm to support arm, depending on specifications and time scales of the processes in the respective stations.P7516PC00

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[0162] In one embodiment of the present disclosure, at least one of the support arms further comprises a rotatable cantilever, the at least one rotatable cantilever being configured to rotate onto and mechanically engage with the elongated continuous flexible substrate to allow one section of said substrate to move while another section is held still, and / or electrically connect to said substrate, optionally to provide a short circuit. The rotatable cantilever provides a mechanism for selective control over the movement of the substrate, enabling localized stabilization or temporary immobilization of a portion of the substrate while other sections continue to advance through the roll-to-roll system. This configuration allows for greater precision in processing, particularly in synthesis or testing steps where controlled positioning is beneficial.

[0163] The rotatable cantilever may be configured to apply a controlled force to the substrate, ensuring stable contact without causing excessive pressure or damage. In some embodiments, the cantilever may operate passively by leveraging the inherent tension of the substrate, or it may be actively controlled to engage or disengage based on predefined processing conditions. The ability to hold one section of the substrate stationary while permitting movement in another section enhances the adaptability of the system for high-precision material deposition, patterning, or analysis. This feature may also facilitate real-time adjustments in substrate positioning, allowing for improved reproducibility and quality control in high-throughput material screening processes including high-throughput development processes of catalysts and coatings.

[0164] The at least one rotatable cantilever addresses the challenge of coordinating processes in different stations that operate on significantly different time scales. For example, a cleaning or preprocessing step may require only a few minutes, whereas a downstream synthesis operation may take tens of minutes. In such cases, the rotatable cantilever can selectively immobilize a section of the elongated continuous flexible substrate while allowing another section to advance, ensuring that the substrate movement aligns with the processing durations of each station. This functionality enhances the system’s versatility by enabling independent timing control across multiple stations, thereby allowing a wider range of station and process combinations to be integrated within the roll-to-roll workflow.P7516PC00

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[0166] Additionally or alternatively, the rotatable cantilever may be configured to electrically connect to the elongated continuous flexible substrate, thereby enabling electrical contact for various processing or testing operations. In some embodiments, the electrical connection may be utilized to establish a short circuit, which can serve specific electrochemical, conductive, or measurement-related functions, such as grounding the substrate, providing a reference potential, or assisting in charge dissipation during electrodeposition or testing.

[0167] In one embodiment of the present disclosure, the system further comprises a platform configured to attach and support the configurable stations. The platform provides a structural foundation for securing the cleaning, synthesis, and testing stations, ensuring stability and precise alignment during operation. By serving as a mounting structure, the platform facilitates modularity, allowing configurable stations to be positioned, replaced, or reconfigured based on specific processing embodiments.

[0168] The platform may comprise a metallic plate with a grid of screw holes, allowing for adjustable positioning and secure attachment of the configurable stations. This gridbased design enables flexible mounting configurations, facilitating rapid reconfiguration of the system to accommodate different processing workflows. The screw holes may be arranged in a standardized pattern to support various station sizes and alignments, ensuring compatibility with different synthesis and testing modules. In some embodiments, the metallic plate may be constructed from a rigid, corrosion-resistant material, such as stainless steel or aluminium, to provide durability and long-term structural integrity. The inclusion of a structured platform enhances the overall reliability and scalability of the system, enabling efficient high-throughput screening of catalysts and catalytic coatings while maintaining controlled and reproducible processing conditions.

[0169] In one embodiment of the present disclosure, the system further comprises an internal closed-loop mechanism configured to transport the elongated continuous flexible substrate through one or more of the configurable cleaning station, the configurable synthesis station, and / or the configurable inline testing station multiple times in a controlled sequence. This closed-loop functionality allows for iterative processing, enabling enhanced synthesis, repeated testing, or multi-stage modifications to theP7516PC00

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[0171] substrate, thereby increasing process flexibility and adaptability to various material processing requirements.

[0172] The internal closed-loop mechanism may include a series of rollers, guiding elements, or programmable transport controls that regulate the movement of the substrate through the system in a predefined sequence. This embodiment allows the substrate to revisit certain stations multiple times, and as such the embodiment can support processes that require layered deposition, multi-step treatments, or incremental modifications to achieve desired material properties. For example, in electrodeposition or chemical coating applications, multiple passes through the synthesis station may enable precise thickness control or composite layer formation. In testing applications, repeated exposure to an inline testing station may allow for real-time monitoring of material changes under controlled conditions.

[0173] The present disclosure also relates to a method for high-throughput fabrication, characterization, and testing of catalysts and / or catalytic coatings, comprising the steps of: providing a modular roll-to-roll system comprising at least one configurable cleaning station, at least one configurable synthesis station downstream of the at least one configurable cleaning station, and at least one configurable inline testing station downstream of the at least one configurable synthesis station; providing an elongated continuous flexible substrate, such as a wire or a dense or porous film, to the modular roll-to-roll system, said substrate configured to carry a plurality of sequential samples through the system; autonomously passing said substrate through the configurable stations of the modular roll-to-roll system to perform high-throughput fabrication, characterization, and testing of catalysts and / or catalytic coatings.

[0174] The method integrates cleaning, synthesis, and testing stations into a single, streamlined process, facilitating efficient, scalable, and reproducible screening of catalysts and catalytic coatings. The method ensures that the substrate autonomously progresses through the configurable stations, where the substrate undergoes surface preparation, material deposition, and performance evaluation, enabling high-throughput synthesis and screening. The method enables precise control over material fabrication by regulating synthesis parameters such as deposition conditions, precursor composition, and processing times. Inline testing stations allow for real-time characterization of the fabricated materials, assessing key properties such asP7516PC00

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[0176] electrochemical performance, structural integrity, and catalytic activity. The presently disclosed method can significantly enhance processing speed, reproducibility, and scalability by reducing or eliminating the need for manual intervention.

[0177] In one embodiment of the present disclosure, the method is used for production of a metallic wire comprising at least one functional coating, such as a coating comprising a catalytically active element . The method may involve the continuous processing of a metallic wire as an elongated continuous flexible substrate, wherein the wire is subjected to sequential fabrication, and testing steps in a modular roll-to-roll system. The use of a metallic wire provides advantages such as high conductivity, mechanical durability, and compatibility with various synthesis and coating techniques, making it suitable for catalytic applications in electrochemical systems, sensors, and industrial catalytic processes.

[0178] The method may include depositing a catalyst or functional coating onto the metallic wire through synthesis techniques such as electrodeposition, chemical vapor deposition, or plasma-enhanced processes. The coated wire may then be tested inline to evaluate coating quality, adhesion, electrochemical performance, or other relevant properties.

[0179] The continuous and automated nature of the roll-to-roll process makes the method suitable for high-throughput screening and optimization of coated metallic wires. The method further reduces material waste and improves reproducibility. By integration of the downstream inline testing station into the roll-to-roll system, the post-processed metallic wire may be tailored for and delivered directly to versatile industrial and research applications.

[0180] In one embodiment of the present disclosure, the method is used for high-throughput experimentation and exploration of material compositions and microstructures. The method enables systematic variation of synthesis parameters, processing conditions, and deposition techniques to rapidly generate and evaluate a diverse set of material compositions and structural configurations. This embodiment facilitates iterative optimization and large-scale screening of functional coatings, catalytic materials, and other engineered surfaces.P7516PC00

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[0182] The method may involve controlled adjustments to precursor concentrations, deposition times, temperatures, electrochemical conditions, or other synthesis parameters to explore a wide range of material properties. Inline characterization and testing stations allow for real-time analysis of microstructural features, such as crystallinity, grain size, phase composition, porosity, or surface roughness. By continuously processing an elongated continuous flexible substrate, the method enables seamless experimentation with minimal material waste and high reproducibility. This approach supports rapid discovery and refinement of materials for applications in catalysis, energy storage, corrosion protection, and advanced functional coatings.

[0183] In one embodiment of the present disclosure, the method is used to optimize the output samples’ quality according to predefined composition, purity, microstructure, functional / optical / structural properties, and / or electrochemical thresholds. The method may involve monitoring and controlling fabrication, characterization, and testing parameters to ensure that the processed samples meet specific quality criteria. This embodiment allows for real-time assessment and adjustment of processing conditions to refine material properties and enhance reproducibility.

[0184] The optimization process may include regulating synthesis parameters such as deposition time, precursor concentration, temperature, applied voltage, or reaction environment to achieve a desired composition, purity, and microstructure.

[0185] Characterization and testing stations may provide inline measurements of functional properties, such as catalytic activity, conductivity, optical transparency, mechanical stability, or corrosion resistance, allowing for immediate feedback and process adjustments. The ability to assess structural features, including crystallinity, grain size, and surface morphology, enables systematic refinement of coatings and materials to enhance their functional performance. By integrating continuous quality assessment with high-throughput screening, the method facilitates the rapid optimization of material formulations and coatings, ensuring they meet predefined thresholds for specific industrial, electrochemical, optical, or structural applications.

[0186] In one embodiment of the present disclosure, the method is used to perform electrolysis, such as electrolysis of water. The method may involve the fabrication, characterization, and testing of catalysts and / or catalytic coatings designed forP7516PC00

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[0188] electrochemical reactions, wherein the processed samples serve as electrodes or electrode components in an electrolysis system. By utilizing a modular roll-to-roll system, the method enables high-throughput screening of catalyst compositions and coatings to enhance the efficiency and durability of electrolysis processes.

[0189] The method may include the deposition of electrocatalyst materials onto an elongated continuous flexible substrate, such as a metallic wire or film, using synthesis techniques such as electrodeposition or chemical vapor deposition. Inline characterization and testing may assess key performance parameters, such as overpotential, current density, or long-term stability under electrochemical conditions. By facilitating systematic evaluation and optimization of electrode materials, the method supports the development of improved catalysts for water electrolysis and other electrochemical applications, such as hydrogen production, carbon dioxide reduction, and industrial electrolysis processes.

[0190] The method for performing electrolysis, such as the electrolysis of water, may be applicable to a wide range of industrial and energy-related applications. Hydrogen generated through water splitting can serve as a clean energy carrier for fuel cells, enabling hydrogen-powered transportation and grid-scale energy storage. Additionally, hydrogen production via electrolysis supports industrial applications, including petroleum refining, ammonia synthesis for fertilizers, and hydrogenation reactions in chemical manufacturing. In emerging energy solutions, water splitting plays a role in artificial photosynthesis and sustainable fuel production by converting renewable energy into hydrogen-based fuels. The oxygen byproduct of water electrolysis may also be utilized in medical applications, wastewater treatment, and industrial combustion processes.

[0191] The present disclosure also relates to any combination of any of the embodiments relating to both method and system described herein.

[0192] Reference numeral list

[0193] 100 modular roll-to-roll system

[0194] 101 elongated continuous flexible substrate, such as a wire or a dense or porous filmP7516PC00

[0195] 36

[0196] 102 input roller configured to deliver an elongated continuous flexible substrate

[0197] 103 configurable cleaning station

[0198] 104 configurable synthesis station

[0199] 105 configurable inline testing station

[0200] 106 output roller configured to collect a post-processed elongated continuous flexible substrate

[0201] 107 cylindrical section, such as a spool, a mandrel, or a reel supporting and transporting the elongated continuous flexible substrate

[0202] 200 modular roll-to-roll system

[0203] 201 input roller configured to deliver an elongated continuous flexible substrate

[0204] 202 elongated continuous flexible substrate being a metallic wire

[0205] 203 support arm to support and guide the metallic wire through successive stations

[0206] 204 configurable cleaning station configured to remove contaminants of the metallic wire

[0207] 205 configurable cleaning station configured to rinse the metallic wire, such as in deionized water

[0208] 206 configurable synthesis station configured for catalytic coating of the metallic wire

[0209] 207 configurable inline testing station configured for electrochemical testing of the coated metallic wire such as for water splitting

[0210] 208 output roller configured to collect a post-processed elongated continuous flexible substrate

[0211] 209 liquid dispensing system

[0212] 210 tube connecting the liquid dispensing system to the configurable cleaning station

[0213] 211 tube connecting the liquid dispensing system to the configurable synthesis station

[0214] 212 tube connecting the liquid dispensing system to the configurable inline testing station

[0215] 213 pump configured to pump liquid from a liquid container through a connecting tube to the configurable inline testing station

[0216] 214 liquid container configured to store a liquidP7516PC00

[0217] 37

[0218] 300 output roller

[0219] 301 cylindrical section comprising guiding tracks configured to keep the metallic wire aligned during winding

[0220] 302 stepper motor configured to drive the cylindrical section

[0221] 303 stepper motor

[0222] 304 elongated continuous flexible substrate being a metallic wire

[0223] 305 platform configured to support the output roller

[0224] 306 stabilizing rod

[0225] Examples

[0226] In this section we provide examples of the present disclosure concerning a modular roll-to-roll system for high-throughput screening of catalysts and / or catalytic coatings. These examples are non-limiting and serve to illustrate possible embodiments and implementations of the present disclosure.

[0227] One embodiment of the presently disclosed modular roll-to-roll system is illustrated in FIG. 2, with an embodiment of the presently disclosed output roller illustrated in FIG. 3. The modular roll-to-roll system of FIG. 2 (200) comprises an input roller (201), two configurable cleaning stations (204, 205), one configurable synthesis station (206) downstream of the two configurable cleaning stations, one configurable inline testing station (207) downstream of the synthesis station, an output roller (207), and a liquid dispensing system (209). All configurable stations and rollers may be mounted on a solid platform to ensure mechanical stability and structural rigidity.

[0228] In the present embodiment, the system is configured to transport a continuous elongated substrate being a flexible metallic wire. The wire diameter may typically be in the range of 0.01 mm to 5 mm. The output roller may typically operate at a slow revolution speed of 0.005 Rounds Per Minute (RPM) to 5 RPM, or at moderate speeds of 5 RPM to 20 RPM. Typical transportation speeds of the wire may be in the range of 0.1 cm / min to 100 cm / min.

[0229] The system is integrated with a liquid dispensing system (209) configured to control the delivery of liquids to various configurable stations via connecting tubes (210, 211, 212) configured to contain various liquids. For example, acidic solutions may be supplied to the configurable cleaning stations, while metal solutions and / or electrolytes may beP7516PC00

[0230] 38

[0231] provided to the configurable synthesis or testing stations or both. The liquid dispensing system (209) may comprise a computational unit, such as a microcontroller, that automates liquid flow control, precisely regulating dispensing volumes and adjusting liquid composition dynamically. The tubing (210, 211, 212) in FIG. 2 is arbitrarily placed, and it should be understood that any dispensing liquid may be provided into any of configurable station (204, 205, 206, 207).

[0232] The input roller (201) is configured to introduce an elongated continuous flexible substrate (202), such as a metallic wire composed of nickel, into the system. The input roller (201) may comprise a spool designed to feed the first configurable cleaning station (204), wherein the metallic wire undergoes surface preparation. In one implementation, the first cleaning station removes contaminants, such as oxide or sulfide surface layers, by exposing the wire to an acidic or alkaline solution.

[0233] Downstream, the second configurable cleaning station (205) rinses the wire in deionized water to eliminate residual acidic solutions before synthesis.

[0234] The configurable synthesis station (206), positioned downstream of the configurable cleaning stations (204, 205), may be configured to perform electrodeposition on the metallic wire either in the form of single element electrodeposition or electrodeposition of a mix of metals such as in a bimetallic, trimetallic or polymetallic alloy. During synthesis, the wire is exposed to an aqueous solution comprising at least one source of metal ions, which are delivered from the liquid dispensing system (209) via connecting tubes (211). The aqueous solution comprising metal ions may exemplary be provided in the form of an aqueous solution of Ni2+-salt exemplary being chloride, bromide, nitrate, or sulfate, preferably chloride and sulfate. The system may comprise a potentiostat to regulate the electrodeposition process of metallic Ni on the wire surface by controlling the potential difference between a working electrode and a reference electrode both of which are submerged in the aqueous electrolyte solution, ensuring precise deposition.

[0235] The solution in the synthesis station may be a composite formulation containing multiple chemical components. The liquid dispensing system (209) may comprise liquid containers (214) for individual prospective reactivities of the synthesis station, such as various metal ion salts, metal ion (coordination) complexes, acids, bases, organic ligands bearing O, N or S coordinating groups, oxidizing agents, reducing agents,P7516PC00

[0236] 39

[0237] nanoparticle dispersions, or surfactants. The liquid dispensing system (209) may be configured to regulate the flow from each liquid container (214) via a microcontroller configured to control a plurality of pumps (213). This enables real-time control over the electrolyte composition, optimizing deposition conditions for the intended use of the functional material, such as catalyst performance.

[0238] The system further comprises a plurality of support arms (203), wherein each support arm may be equipped with individual spools to support and guide the metallic wire through successive stations. These support arms provide structural reinforcement and maintain appropriate wire tension during transport. In one embodiment, the system incorporates one support arm on either side of each configurable station, resulting in a total of eight support arms. The support arms are substantially L-shaped, oriented upside down, and positioned in an alternating configuration along the wire’s transport direction. This arrangement ensures precise alignment and stabilization of the wire as it moves through the system. The working volume of each configurable station is symmetrically positioned between a pair of support arms, optimizing spatial organization and process consistency.

[0239] In one embodiment, two support arms flanking the configurable synthesis station are equipped with rotatable cantilevers. The cantilevers are configured to rotate onto the metallic wire and make electrical contact using brushes composed of a conductive material, such as copper. This configuration provides a means for electrically shortcircuiting a section of the wire during synthesis to prevent interference with the electrodeposition process.

[0240] The configurable inline testing station (206) may be configured for electrochemical testing, such as specifically for water splitting (2H2O — > O2+ 2H2). The testing process may be facilitated by a potentiostat that regulates the applied voltage and records the resulting current response. Real-time monitoring of the water-splitting reaction may be conducted by analyzing current-voltage (or current density-voltage) characteristics. A high-performance electrocatalyst is indicated by a low overpotential, high current density, and stable operation.

[0241] The results of electrochemical testing may be directly correlated with the liquid dispensing system to adjust electrolyte composition in real time. This closed-loopP7516PC00

[0242] 40

[0243] feedback mechanism enables dynamic optimization of synthesis parameters based on testing outcomes. Temperature and potentiostat settings, such as deposition time and current density, may also be adjusted within this closed-loop feedback mechanism to enhance synthesis conditions. Maintaining precise temperature control can influence reaction kinetics, nucleation rates, and coating uniformity, particularly in electrodeposition and catalytic layer formation. Additionally, regulating deposition time ensures controlled film thickness, while adjusting current density directly affects the morphology, adhesion, and electrochemical properties of the deposited material.

[0244] The system comprises an output roller (208) configured to collect the post-processed metallic wire. In one embodiment, the output roller (300) comprises a cylindrical section (301) configured to collect and wind the elongated continuous flexible substrate, such as a metallic wire after having passed through the configurable stations of the system. The output roller (300) may comprise a stabilizing rod (306) and a platform (305). The stabilizing rod (306) may be directly supported by the platform (305) via a drilled hole in the platform. The stabilizing rod (306) may be directly and coaxially connected to the cylindrical section (301) and provide mechanical rigidity and stability. The cylindrical section (301) may comprise grooves or guiding tracks to keep the metallic wire aligned during winding. The cylindrical section (301) may be configured to slide along the stabilizing rod (306) in a direction substantially perpendicular to the direction of wire transport (along the extending direction of the stabilizing rod (306)) to maintain precise alignment during winding. The output roller may comprise a stepper motor (302, 303) configured to power and rotate the cylindrical section (301) to precisely control substrate collection.

[0245] Testing results of the configurable inline testing station may be correlated with parameters controlling the synthesis operations via the backtracking mechanism, enabling direct mapping between a specific section of the processed metallic wire, the synthesis parameters at the configurable synthesis station (206), and the currentvoltage characteristics measured at the configurable inline testing station (207). This mapping allows for high-throughput screening of electrolyte formulations and synthesis conditions, efficiently navigating complex multi-dimensional parameter spaces.

[0246] The output roller may comprise a backtracking mechanism that records and correlates synthesis operations with specific positions along the substrate. By maintaining wireP7516PC00

[0247] 41

[0248] tension and leveraging its rigidity, this mechanism ensures that deposition parameters, reactant concentrations, and processing durations can be directly and unambiguously linked to material properties and performance metrics. This functionality enhances process control and facilitates systematic catalyst and coating optimization.

[0249] FIG. 4 illustrates an example embodiment of an automated catalyst synthesis and testing platform configured as a modular roll-to-roll system according to the present disclosure.

[0250] The system comprises a transport mechanism configured to move an elongated continuous flexible substrate, such as a metallic wire, through a sequence of processing stations. In the illustrated embodiment, the substrate is unwound from an input spool and transported through the system using a motor-driven transport mechanism, such as a stepper motor coupled to rollers configured to control substrate movement and tension.

[0251] The substrate is first guided through a cleaning station configured to remove surface contaminants from the substrate prior to catalyst deposition. The cleaning station may contain acidic solutions, rinsing liquids, or other surface-preparation media.

[0252] Downstream of the cleaning station, the substrate enters a synthesis station configured to deposit catalytic materials onto the substrate. In the illustrated embodiment, the synthesis station comprises an electrochemical deposition cell containing an electrolyte solution supplied by a liquid dispensing system. The substrate may function as a working electrode during electrodeposition, while a counter electrode is arranged within the deposition cell.

[0253] Following synthesis, the coated substrate is transported into an electrochemical testing station configured to evaluate catalytic activity of the deposited coating. The testing station comprises an electrolyte reservoir and an electrochemical measurement configuration including a working electrode, a counter electrode, and a reference electrode.

[0254] The electrochemical testing station may be connected to a potentiostat configured to control the potential difference between the electrodes and measure the resultingP7516PC00

[0255] 42

[0256] current response during electrochemical testing procedures such as cyclic voltammetry or other electrochemical characterization techniques.

[0257] The system further comprises a liquid distribution system configured to supply precursor solutions to the synthesis station and testing electrolytes to the electrochemical testing station. The liquid distribution system may include reservoirs, pumps, valves, and conduits configured to deliver liquids in controlled quantities to the respective stations.

[0258] A computational control unit may be configured to coordinate operation of the transport mechanism, liquid dispensing system, and electrochemical measurement system, thereby enabling automated synthesis and testing of sequential catalyst samples along the substrate.

[0259] After testing, the processed substrate is collected on an output spool, allowing continuous fabrication and evaluation of multiple catalyst samples along the length of the substrate.

[0260] The embodiment illustrated in FIG. 4 demonstrates how a roll-to-roll transport system may integrate substrate cleaning, catalyst synthesis, and inline electrochemical testing in a single automated platform for high-throughput screening and optimization of catalyst compositions.

[0261] Example - High-throughput electrochemical testing of Ni-Mo electrocatalysts

[0262] A modular roll-to-roll catalyst synthesis and testing system according to the present disclosure was used to fabricate and electrochemically evaluate nickel-molybdenum electrocatalyst coatings for hydrogen evolution in alkaline water electrolysis.

[0263] A continuous nickel wire substrate having a diameter of approximately 0.4 mm was provided as an elongated continuous flexible substrate. The nickel wire was transported through the modular roll-to-roll system using an input roller and a plurality of support arms.

[0264] Prior to synthesis, the wire was cleaned in a cleaning station by immersion in an acidic solution comprising approximately 3 M hydrochloric acid, followed by rinsing inP7516PC00

[0265] 43

[0266] deionized water. The cleaned wire was subsequently transported to a synthesis station configured for electrodeposition of Ni-Mo electrocatalyst coatings. Electrodeposition was carried out from aqueous electrolyte solutions comprising nickel and molybdenum precursors. In one implementation, two deposition solutions were used:

[0267] • Solution 1 : sodium molybdate, nickel sulfate, and sodium citrate

[0268] • Solution 2: nickel sulfate, sodium molybdate, and sodium citrate.

[0269] During electrodeposition, the nickel wire served as the working electrode and a platinum wire served as the counter electrode.

[0270] The system was configured to vary multiple synthesis parameters including:

[0271] • deposition current density

[0272] • deposition time

[0273] • deposition temperature

[0274] • precursor concentrations.

[0275] This enabled the fabrication of multiple sequential catalyst samples along the continuous substrate. Following synthesis, the coated wire was transported directly into a configurable inline testing station configured for electrochemical testing.

[0276] Electrochemical characterization was performed in an alkaline electrolyte comprising approximately 6.9 M potassium hydroxide at a temperature of approximately 80 °C.

[0277] A three-electrode configuration was used comprising:

[0278] • the coated nickel wire as a working electrode,

[0279] • a counter electrode, and

[0280] • a reversible hydrogen reference electrode.

[0281] The electrochemical performance of each catalyst sample was evaluated using cyclic voltammetry. For each catalyst sample, an accelerated stress test was performed consisting of approximately 100 cyclic voltammetry scans between -300 mV and 400 mV versus the reversible hydrogen electrode at a scan rate of approximately 50 mV S’1.

[0282] Representative cyclic voltammetry curves obtained during such electrochemical testing are illustrated in FIG. 5A, which shows the electrochemical response of a catalyst coating during repeated potential sweeps.P7516PC00

[0283] 44

[0284] For each cycle, the overpotential required to achieve a current density of approximately -10 mA cm-2was determined.

[0285] FIG. 5B illustrates the determination of a performance metric derived from the electrochemical testing, wherein the overpotential values obtained during sequential cyclic voltammetry scans are used to generate a degradation curve and an average overpotential metric.

[0286] The average overpotential across the cyclic voltammetry scans was used as a performance metric reflecting both catalytic activity and stability of the catalyst coating.

[0287] Using the roll-to-roll system, sequential catalyst samples were fabricated and tested in an automated workflow. The system was capable of synthesizing and evaluating large numbers of catalyst compositions in a continuous process.

[0288] The experiments identified Ni-Mo catalyst compositions exhibiting average overpotentials of approximately 60-70 mV at -10 mA cm-2under alkaline conditions, indicating high catalytic activity for the hydrogen evolution reaction.

[0289] This example demonstrates that the modular roll-to-roll system enables automated high-throughput fabrication and inline electrochemical testing of catalyst coatings, allowing rapid optimization of catalyst compositions.

[0290] Example - Optimization of Ni-Mo electrocatalysts using high-throughput electrochemical testing

[0291] A modular roll-to-roll catalyst synthesis and testing system according to the present disclosure was used to optimize nickel-molybdenum electrocatalyst coatings for the hydrogen evolution reaction.

[0292] A continuous nickel wire substrate was transported through the roll-to-roll system through sequential stations including a cleaning station, a synthesis station, and an inline electrochemical testing station.P7516PC00

[0293] 45

[0294] Ni-Mo coatings were deposited onto the nickel wire using electrodeposition in an aqueous electrolyte containing nickel sulfate and sodium molybdate. The synthesis station was configured to vary multiple synthesis parameters including:

[0295] • deposition current density

[0296] • deposition time

[0297] • deposition temperature

[0298] • precursor concentration.

[0299] The explored parameter space included:

[0300] • current densities between approximately -1 mA cm-2and -200 mA cm-2• deposition times between approximately 60 s and 600 s

[0301] • deposition temperatures between approximately 30 °C and 70 °C.

[0302] After deposition, the coated substrate was transported to the inline testing station. Electrochemical testing was performed in an alkaline electrolyte comprising potassium hydroxide. Each catalyst sample underwent cyclic voltammetry measurements to determine the catalytic activity toward hydrogen evolution. Examples of cyclic voltammetry measurements obtained during such testing are illustrated in FIG. 5A.

[0303] In one implementation, an accelerated stress test was performed by conducting approximately 100 cyclic voltammetry scans between -300 mV and 400 mV versus the reversible hydrogen electrode. For each cycle the overpotential at -10 mA cm-2was determined and averaged across the scans to evaluate catalyst performance. The resulting degradation behaviour and averaged overpotential metric are illustrated in FIG. 5B.

[0304] Using this high-throughput workflow, catalyst compositions exhibiting overpotentials of approximately 60-70 mV at -10 mA cm-2were identified.

[0305] The experiment demonstrates that the roll-to-roll system enables rapid optimization of electrocatalyst compositions through automated synthesis and inline electrochemical testing.P7516PC00

[0306] 46

[0307] Example - Discovery of Ni-Cr electrocatalysts using a roll-to-roll synthesis and testing platform

[0308] The modular roll-to-roll catalyst development system was also used to discover nickelchromium catalyst compositions suitable for alkaline water electrolysis. In this experiment the system was configured to fabricate sequential catalyst coatings along a metallic wire substrate using electrodeposition.

[0309] Multiple electrolyte formulations containing nickel and chromium precursor salts were supplied to the synthesis station via the liquid dispensing system. The deposition conditions were varied to generate a series of Ni-Cr alloy coatings. After synthesis, the coated substrate was transported to an inline electrochemical testing station where catalytic activity and stability were evaluated under alkaline electrolysis conditions. Electrochemical testing of the Ni-Cr catalyst coatings was performed using cyclic voltammetry measurements similar to those illustrated in FIG. 5A, and performance metrics based on overpotential behaviour as illustrated in FIG. 5B. The testing system measured the electrochemical performance of the catalysts and identified regions of the Ni-Cr composition space exhibiting improved catalytic stability compared with Ni-Mo electrocatalysts.

[0310] The experiment demonstrates that the roll-to-roll system can autonomously discover improved catalyst compositions by combining automated synthesis with inline electrochemical evaluation.

[0311] Example - Electrochemical testing of catalyst coatings for alkaline water electrolysis A modular roll-to-roll catalyst fabrication and testing system was used to evaluate catalyst coatings under conditions representative of industrial alkaline water electrolysis.

[0312] A continuous nickel wire substrate coated with catalytic material was transported through the testing station containing an aqueous alkaline electrolyte comprising potassium hydroxide. The electrochemical testing station included:

[0313] • a working electrode formed by the coated wire substrate

[0314] • a counter electrode

[0315] • a reference electrode.P7516PC00

[0316] 47

[0317] The electrolyte was maintained at approximately 80 °C to emulate operating conditions of alkaline electrolyzers. Electrochemical characterization was performed using cyclic voltammetry and current-voltage measurements to evaluate hydrogen evolution performance. Representative electrochemical response curves obtained during such testing are illustrated in FIG. 5A. The catalytic activity was determined by measuring the overpotential required to reach a current density of -10 mA cm-2. The determination of this performance metric from repeated electrochemical measurements is illustrated in FIG. 5B.

[0318] The electrochemical testing results were correlated with the synthesis conditions used to produce each catalyst coating.

[0319] This experiment demonstrates that the roll-to-roll system enables continuous fabrication and electrochemical evaluation of catalyst materials for water electrolysis.

[0320] Items

[0321] 1. A modular roll-to-roll system for high-throughput screening of catalysts and / or catalytic coatings, the system configured to transport an elongated continuous flexible substrate through a plurality of configurable stations, the elongated continuous flexible substrate configured to carry a plurality of sequential samples through the system for sequential screening of the sequential samples, the system comprising:

[0322] at least one configurable cleaning station configured to initially clean the substrate as it passes through said at least one configurable cleaning station; and / or

[0323] at least one configurable synthesis station located downstream of the at least one configurable cleaning station and configured to perform a sequence of synthesis operations to create sequential samples on the substrate as the substrate passes through said at least one configurable synthesis station; and / or

[0324] at least one configurable inline testing station located downstream of the at least one configurable synthesis station and configured to sequentially test the quality of and / or characterize the sequential samples as the substrate passes through said testing station.P7516PC00

[0325] 48

[0326] 2. The system according to any one of the preceding items, configured to operate with the elongated continuous flexible substrate being a wire.

[0327] 3. The system according to item 2, further configured to operate with the wire being a wire composed of a metal or a metal alloy, such as a metallic wire comprising platinum, gold, silver, copper, nickel, titanium, tungsten, aluminium, or stainless steel.

[0328] 4. The system according to item 2, further configured to operate with the wire being a non-metallic wire, such as a non-metallic wire comprising carbon fibres, carbon nanotubes, or graphite.

[0329] 5. The system according to any one of the preceding items, configured to operate with the elongated continuous flexible substrate being a dense or porous film, such as a foam, a mesh, or a sinter.

[0330] 6. The system according to any one of the preceding items, configured to operate with the sequential samples comprising particles, such as nanoparticles.

[0331] 7. The system according to any one of the preceding items, wherein at least one of the configurable inline testing stations is configured for electrochemical testing, such as cyclic voltammetry, linear sweep voltammetry, electrochemical impedance spectroscopy, chronoamperometry, chronopotentiometry, Tafel analysis, and / or corrosion testing.

[0332] 8. The system according to any one of the preceding items, wherein at least one of the configurable inline testing stations is configured for performing inline characterization, such as with X-ray diffraction (XRD), infrared (IR) spectroscopy, ultraviolet-visible (LIV-VIS) spectroscopy, and / or Raman spectroscopy.

[0333] 9. The system according to any one of the preceding items, wherein the at least one synthesis operation is one or more selected from electrodeposition, chemical coating, metallic leaching, and / or alloying.P7516PC00

[0334] 49

[0335] 10. The system according to any one of the preceding items, wherein the at least one configurable synthesis station is configured for electrodeposition techniques, such as potentiostatic or galvanostatic electrochemical deposition, direct current electrodeposition, pulse electrodeposition, reverse pulse electrodeposition, electroless deposition, template-assisted electrodeposition, and / or high-voltage electrodeposition.

[0336] 11. The system according to any one of the preceding items, wherein the at least one configurable synthesis station is configured for performing chemical and electrochemical coating, such as chemical vapor deposition, physical vapor deposition, sol-gel coating, spray pyrolysis, spin coating, dip coating, spray coating, atomic layer deposition, and / or layer-by-layer deposition.

[0337] 12. The system according to any one of the preceding items, wherein the at least one configurable synthesis station is configured for specialized electrodeposition and coating techniques, such as hydrothermal electrodeposition, anodization, plasma electrolytic oxidation, electrophoretic deposition, brush plating, magnetron-assisted coating, and / or plasma-enhanced electrodeposition.

[0338] 13. The system according to any one of the preceding items, further comprising a post-processing testing station, such as configured for tensile testing, flexural or bend testing, adhesion testing, hardness testing, impact resistance testing, thickness measurements, surface roughness testing, thermal testing, fatigue testing, conductivity testing, magnetic susceptibility testing, superconductivity testing, visual and optical inspection, load or compression testing, residual stress testing, and / or creep testing.

[0339] 14. The system according to any one of the preceding items, further comprising an input roller configured to deliver an elongated continuous flexible substrate.

[0340] 15. The system according to any one of the preceding items, further comprising an output roller configured to collect a post-processed elongated continuous flexible substrate.P7516PC00

[0341] 50

[0342] 16. The system according to item 14 or 15, wherein the input roller and / or the output roller comprise a cylindrical section, such as a spool, a mandrel, or a reel, configured to wind an elongated continuous flexible substrate such as a wire or a film.

[0343] 17. The system according to any one of the preceding items, further comprising a liquid dispensing system configured to control the delivery of liquids to the at least one configurable cleaning station, the at least one configurable synthesis station, and / or the at least one configurable inline testing station.

[0344] 18. The system according to item 17, wherein the liquid dispensing system is configured to deliver liquids to the at least one configurable cleaning stations, the liquid comprising deionized water, acidic solutions, metal-ion solutions, transition-metal ion solutions, alkaline solutions, detergent solutions, surfactant solutions, and / or solvent mixtures.

[0345] 19. The system according to any one of the preceding items, wherein the liquid dispensing system is configured to deliver liquids for the at least one configurable synthesis station, the liquid comprising electrolytes, precursors for chemical coatings, organic coating solutions, and / or catalyst particles.

[0346] 20. The system according to any one of the preceding items, wherein the liquid dispensing system is configured to deliver liquids for the at least one configurable inline testing station, the liquid comprising electrochemical testing solutions, indicator solutions, and / or cleaning or rinsing solutions.

[0347] 21. The system according to any one of the preceding items, further comprising a control mechanism for controlling the at least two working electrodes of the at least one configurable inline testing station.

[0348] 22. The system according to item 21, wherein the control mechanism for controlling the at least two working electrodes is a potentiostat.

[0349] 23. The system according to any one of the preceding items, further comprising a backtracking device configured to monitor and correlate at least one synthesisP7516PC00

[0350] 51

[0351] operation with a position along an elongated continuous flexible substrate.

[0352] 24. The system according to any one of the preceding items, further comprising at least one configurable drying and / or heating station.

[0353] 25. The system according to any one of the preceding items, further comprising at least one configurable pretreatment station configured to prepare a part of the elongated continuous flexible substrate and / or sequential samples prior to entering the at least one configurable synthesis station.

[0354] 26. The system according to any one of the preceding items, wherein at least one of the configurable cleaning stations comprises a cleaning step comprising the use of acid to remove a passivating oxide layer.

[0355] 27. The system according to any one of the preceding items, further comprising a plurality of support arms, wherein said support arms comprise at least one cylindrical section, such as a spool, mandrel, or reel, to support and transport the elongated continuous flexible substrate, wherein the plurality of support arms are configured to pass said substrate from one configurable station to a downstream configurable station.

[0356] 28. The system according to item 27, wherein at least one of the support arms further comprises a rotatable cantilever, the at least one rotatable cantilever being configured to rotate onto and mechanically engage with the elongated continuous flexible substrate to allow one section of said substrate to move while another section is held still, and / or electrically connect to said substrate, optionally to provide a short circuit.

[0357] 29. The system according to any one of the preceding items, further comprising a platform configured to attach and support the configurable stations.

[0358] 30. The system according to any one of the preceding items, further comprising an internal closed-loop mechanism configured to transport the elongated continuous flexible substrate through one or more of the configurable cleaningP7516PC00

[0359] 52

[0360] station, the configurable synthesis station, and / or the configurable inline testing station multiple times in a controlled sequence.

[0361] 31. A method for high-throughput fabrication, characterization, and testing of catalysts and / or catalytic coatings, comprising the steps of:

[0362] providing a modular roll-to-roll system comprising at least one configurable cleaning station, at least one configurable synthesis station downstream of the at least one configurable cleaning station, and at least one configurable inline testing station downstream of the at least one configurable synthesis station;

[0363] providing an elongated continuous flexible substrate, such as a wire or a dense or porous film to the modular roll-to-roll system, said substrate configured to carry a plurality of sequential samples through the system; autonomously passing said substrate through the configurable stations of the modular roll-to-roll system to perform high-throughput fabrication, characterization, and testing of catalysts and / or catalytic coatings.

[0364] 32. The method according to any one of the preceding items, used for production of a metallic wire comprising at least one functional coating, such as a coating comprising a catalytically active element.

[0365] 33. The method according to any one of the preceding items, used for high- throughput experimentation and exploration of material compositions and microstructures.

[0366] 34. The method according to any one of the preceding items, used to optimize the output samples’ quality according to predefined composition, purity, microstructure, functional / optical / structural properties, and / or electrochemical thresholds.

[0367] 35. The method according to any one of the preceding items, used to perform electrolysis, such as electrolysis of water.

Claims

1. P7516PC0053Claims1. A modular roll-to-roll system for high-throughput fabrication and screening of catalysts and / or catalytic coatings, the system configured to transport an elongated continuous flexible substrate through a plurality of configurable stations, the elongated continuous flexible substrate configured to carry a plurality of sequential samples through the system for sequential screening of the sequential samples, the system comprising:at least one configurable cleaning station configured to initially clean the substrate as it passes through said at least one configurable cleaning station;at least one configurable synthesis station located downstream of the at least one configurable cleaning station and configured to perform a sequence of synthesis operations to create sequential catalyst and / or catalytic coating samples on the substrate as the substrate passes through said at least one configurable synthesis station; andat least one configurable inline testing station located downstream of the at least one configurable synthesis station and configured to sequentially test the quality of and / or characterize the sequential catalyst and / or catalytic coating samples by performing electrochemical testing of the sequential samples while the substrate passes through said testing station.

2. The system according to claim 1 , configured to operate with the elongated continuous flexible substrate being a wire.

3. The system according to any one of the preceding claims, wherein the at least one configurable inline testing station comprises a potentiostat configured to control a potential between a working electrode and a reference electrode while measuring current.

4. The system according to any one of the preceding claims, wherein the electrochemical testing is selected from the group of: cyclic voltammetry, linear sweep voltammetry, electrochemical impedance spectroscopy, chronoamperometry, chronopotentiometry, Tafel analysis, and corrosion testing.P7516PC00545. The system according to any one of the preceding claims, wherein the at least one configurable inline testing station is configured to determine catalytic activity of the sequential samples for electrochemical reactions, such as water splitting.

6. The system according to any one of the preceding claims, wherein the at least one configurable inline testing station is configured to perform electrochemical measurements of the sequential catalyst and / or catalytic coating samples.

7. The system according to any one of the preceding claims, wherein the at least one configurable inline testing station is configured to perform electrochemical measurements using a three-electrode configuration comprising a working electrode, a counter electrode, and a reference electrode.

8. The system according to any one of the preceding claims, wherein the at least one configurable inline testing station is is configured to determine an overpotential required to achieve a predefined current density.

9. The system according to any one of the preceding claims, wherein the at least one configurable inline testing station is configured to perform repeated cyclic voltammetry scans of the sequential catalyst samples.

10. The system according to claim 9, wherein the repeated cyclic voltammetry scans are performed as part of an accelerated electrochemical stress test.

11. The system according to any one of the preceding claims, wherein the at least one configurable inline testing station is configured to perform quality assessment of the sequential catalyst and / or catalytic coating samples while the substrate passes through said testing station.

12. The system according to any one of the preceding claims, wherein the electrochemical testing is performed in an electrolyte contained in the inline testing station.P7516PC005513. The system according to any one of the preceding claims, wherein at least one of the configurable inline testing stations is configured for performing additional inline characterization of the electrochemically tested catalyst samples, such as with X-ray diffraction (XRD), infrared (IR) spectroscopy, ultraviolet-visible (UV- VIS) spectroscopy, and / or Raman spectroscopy.

14. The system according to any one of the preceding claims, wherein the at least one synthesis operation is selected from electrodeposition, chemical coating, metallic leaching, and alloying, or any combination thereof, to form electrocatalyst coatings and / or catalytically active materials for electrochemical reactions.

15. The system according to any one of the preceding claims, wherein the at least one configurable synthesis station is configured for performing chemical and electrochemical coating to deposit catalytically active materials for electrochemical reactions, such as chemical vapor deposition, physical vapor deposition, sol-gel coating, spray pyrolysis, spin coating, dip coating, spray coating, atomic layer deposition, and / or layer-by-layer deposition.

16. The system according to any one of the preceding claims, comprising a postprocessing testing station, such as configured for tensile testing, flexural or bend testing, adhesion testing, hardness testing, impact resistance testing, thickness measurements, surface roughness testing, thermal testing, fatigue testing, conductivity testing, magnetic susceptibility testing, superconductivity testing, visual and optical inspection, load or compression testing, residual stress testing, and / or creep testing.

17. The system according to any one of the preceding claims, comprising an output roller configured to collect a post-processed elongated continuous flexible substrate.

18. The system according to any one of the preceding claims, comprising a liquid dispensing system configured to control the delivery of liquids to the at least one configurable cleaning station, the at least one configurable synthesisP7516PC0056station, and / or the at least one configurable inline testing station.

19. The system according to any one of the preceding claims, further comprising at least one configurable drying and / or heating station.

20. The system according to any one of the preceding claims, wherein the at least one configurable cleaning station is configured to execute a cleaning step comprising the use of acid to remove a passivating oxide layer.

21. The system according to any one of the preceding claims, comprising a plurality of support arms, wherein said support arms comprise at least one cylindrical section, such as a spool, mandrel, or reel, to support and transport the elongated continuous flexible substrate, wherein the plurality of support arms are configured to pass said substrate from one configurable station to a downstream configurable station.

22. A method for high-throughput fabrication, characterization, and electrochemical testing of catalysts and / or catalytic coatings, comprising the steps of:providing a modular roll-to-roll system comprising at least one configurable cleaning station, at least one configurable synthesis station downstream of the at least one configurable cleaning station, and at least one configurable inline testing station downstream of the at least one configurable synthesis station;providing an elongated continuous flexible substrate, such as a wire or a dense or porous film to the modular roll-to-roll system, said substrate configured to carry a plurality of sequential samples through the system; autonomously passing said substrate through the configurable stations of the modular roll-to-roll system to perform high-throughput fabrication characterization, and electrochemical testing of the sequential catalyst samples.

23. The method according to claim 22, used for production of a metallic wire comprising at least one functional coating, such as a coating comprising a catalytically active element.P7516PC005724. The method according to any one of the preceding claims 22-23, used to optimize the output samples’ quality according to predefined composition, purity, microstructure, functional / optical / structural properties, and / or electrochemical thresholds.

25. The method according to any one of claims 22-24, wherein the electrochemical testing comprises cyclic voltammetry measurements performed on the sequential catalyst samples.

26. The method according to any one of claims 22-25, wherein the modular roll-to- roll system is the system according to any one of the preceding claims 1-21.

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