This research uses a traffic analogy to explain gas transport challenges in carbon dioxide electrolysis devices. Despite identical porosity, microstructural connectivity determines performance under flooding conditions. Computational modelling reveals how pathway structure affects efficiency, guiding design improvements that enhance CO₂ conversion into fuels and chemicals, supporting scalable and cleaner energy technologies.

This research advances metal additive manufacturing by replacing wasteful machining with laser-based powder fusion. Inspired by baking, printed metal parts are optimized through microstructural analysis. The approach produces complex geometries with equal or superior strength and durability while significantly reducing material waste, enabling cleaner, more sustainable manufacturing.