NETL Earns Prestigious R&D 100 Recognition as Co-Developer of REFLEX

NETL received a 2026 R&D 100 Award for its contributions that led to the development of Real-time Embedded Feedback and Layered Excitation (REFLEX) - technology that addresses fundamental challenges limiting the efficient use of solid oxide fuel cells (SOFCs) and solid oxide electrolysis cells (SOECs).

The project was led by Kevin P. Chen, the Paul E. Lego Professor and Vice Chair for Research, Department of Electrical and Computer Engineering at the University of Pittsburgh Swanson School of Engineering. Researchers at NETL and the Idaho National Laboratory served as co-developers.

Electrochemical energy systems such as SOFCs and SOECs are emerging as critical technologies. SOFCs convert chemical energy into electricity, and SOECs use electricity to convert water/carbon dioxide into chemical fuels for resilient power generation.

However, current systems generally lack embedded internal sensors and active control architectures capable of directly monitoring or regulating internal thermal gradients, localized hot spots, and degradation processes.

"Existing systems rely on sparse external measurements that cannot directly monitor these internal parameters, resulting in reduced efficiency, accelerated degradation, and long startup times. REFLEX fundamentally changes this paradigm," said NETL researcher Michael Buric, an expert in sensor technologies who worked on the project.

"Through additive manufacturing, REFLEX integrates distributed fiber-optic sensors, embedded heating elements, electrical conductors, and functional pathways directly into the SOFC and SOEC architecture," Buric said.

By embedding distributed sensing and active control directly into the interconnect plate of the device, REFLEX provides enhanced reliability, reduced degradation, and improved operational efficiency.

According to the developers, REFLEX is the first technology capable of simultaneously providing distributed sensing, active thermal control, and intelligent operation within a single monolithically manufactured interconnect component.

The technology provides real-time distributed temperature and strain monitoring inside operating stacks, the modular physical assembly where multiple individual electrochemical cells are layered, and rapid startup and localized thermal balancing through embedded heating elements.

REFLEX also enables digital-twin capabilities for intelligent operation of SOFCs and SOECs. Digital twins collect real-time data from sensors, Internet of Things devices, and other data streams to monitor SOFC and SOEC performance and predict maintenance needs, preventing unplanned downtimes.

The developers noted that REFLEX has attracted strong interest from industry stakeholders spanning the electrochemical energy supply chain, including system developers, advanced manufacturing organizations, and energy technology companies.

Established in 1963, the R&D 100 Awards program is the only science and technology awards competition that recognizes new commercial products, technologies, and materials for their technological significance that are available for sale or license.

The R&D 100 Awards program identifies and celebrates the top 100 revolutionary technologies of the past year. The 2026 R&D 100 gala banquet will be held at the Grand Hyatt Scottsdale Resort in Arizona in November.

NETL is a U.S. Department of Energy (DOE) national laboratory dedicated to innovating and accelerating the nation's energy solutions in hydrocarbons, geothermal energy, and critical minerals production. The Lab further strengthens its impact by engaging with industry, academia, and other stakeholders through four strategically located Centers of Excellence: Coal, Critical Minerals & Advanced Alloys, Oil & Gas, and Geothermal. With research sites in Albany, Oregon; Morgantown, West Virginia; and Pittsburgh, Pennsylvania, NETL operates as one laboratory to create advanced energy technologies that support DOE's mission and enable affordable, reliable, and secure energy to fuel human prosperity.