BASF’s Ultrason® S enables durable and lightweight electrolyzer stacks by Stargate Hydrogen for scalable green hydrogen production

Ultrason® for lightweight and durable frames in electrolyzer stacks
Thanks to BASF’s specialty plastic Ultrason®, the frames in Stargate Hydrogen’s AWE stacks are large, robust, and durable.
Photo: Stargate Hydrogen/BASF 2025

(IN BRIEF) BASF’s Ultrason® S polysulfone is being deployed by Stargate Hydrogen in its Stellar alkaline water electrolyzer stacks, replacing metals like nickel to deliver lighter, stronger, and more sustainable solutions for green hydrogen production. The high-performance thermoplastic withstands extreme chemical and thermal conditions while enabling greater design flexibility. Stargate Hydrogen CEO Marko Virkebau highlighted the role of Ultrason® in lowering costs and improving efficiency, while BASF’s Jochen Schmid emphasized its contribution to scaling up hydrogen production for the clean energy transition. With frames of up to 85 cm and long operational lifespans, the Stellar stacks provide durable, cost-effective performance for applications in heavy industry and transport. BASF offers a dedicated Ultrason® portfolio for AWE, PEM, and AEM electrolyzers and will present its solutions at K 2025 in Düsseldorf.

(PRESS RELEASE) LUDWIGSHAFEN, 15-Sep-2025 — /EuropaWire/ — BASF’s high-performance thermoplastic Ultrason® S is now being used by Stargate Hydrogen in the frames of its Stellar series alkaline water electrolyzer (AWE) stacks, enabling lighter, more durable, and cost-efficient systems for green hydrogen production. By replacing nickel and other metals with polysulfone, the stacks gain significant advantages in weight reduction, design flexibility, and long-term reliability under harsh operating conditions. The collaboration between BASF and Stargate Hydrogen demonstrates how advanced materials can support the scalability and economic viability of hydrogen technologies.

Alkaline electrolyzers remain the most proven and robust technology for hydrogen generation. Stargate Hydrogen’s Stellar stacks, designed with frames of up to 85 cm in diameter, showcase how BASF’s Ultrason® enables resilience at high temperatures and pressures. Offering outstanding chemical resistance, compression strength, and hydrolytic stability, Ultrason® S withstands current operating conditions of 90 °C and is suitable for next-generation systems exceeding 100 °C. The result is a stack engineered for long lifespans, reducing downtime and maintenance costs, and ensuring dependable hydrogen production for applications in industries such as heavy transport, steel, and chemicals.

“Stargate Hydrogen manufactures electrolyzer stacks to empower system integrators with the most flexible and scalable technology,” said Marko Virkebau, CEO of Stargate Hydrogen. “We build upon the best aspects of AWE technology and complement it with breakthrough materials. This is why we chose BASF’s Ultrason®: it combines lightweight properties with outstanding performance, helping us to improve efficiency and lower the cost of electrolyzers.”

Jochen Schmid from BASF’s Global Business Development Ultrason® team added:
“With Ultrason®, our customers can upscale green hydrogen production, thus advancing the transition to clean energy. Its performance under the harsh conditions of water electrolysis makes it the ideal material for a range of electrolyzer technologies. We are proud to support Stargate Hydrogen in its scale-up strategy — from selecting the right Ultrason® grade to final frame production.”

BASF has developed a tailored Ultrason® portfolio to meet the needs of AWE, proton exchange membrane (PEM), and anion exchange membrane (AEM) electrolyzers. Its range of polyarylethersulfones — including polysulfone (Ultrason® S), polyethersulfone (Ultrason® E), and polyphenylsulfone (Ultrason® P) — combines durability, chemical resistance, and thermal stability for use in frames, gaskets, and separator membranes. Beyond energy, Ultrason® products are widely used in water filtration, consumer goods, and lightweight automotive and aerospace components, substituting metals, glass, and ceramics in demanding applications.

BASF will showcase these innovations at K 2025 in Düsseldorf, Hall 5 Booth C21/D21.

About BASF at K 2025: Welcome to #OurPlasticsJourney!

#OurPlasticsJourney continues in 2025 at K! Join us at our booth in Hall 5, C21/D21 and discover how to start your green transformation. At BASF, we look at the entire lifecycle of plastics with Make, Use and Recycle. Come and explore sustainability and innovation in high-performance plastics at K 2025. K is the #1 trade fair for plastics and rubber and will take place in Duesseldorf, Germany, from October 8 to 15, 2025. Visit www.plastics.basf.com/K2025.
About BASF

At BASF, we create chemistry for a sustainable future. Our ambition: We want to be the preferred chemical company to enable our customers’ green transformation. We combine economic success with environmental protection and social responsibility. Around 112,000 employees in the BASF Group contribute to the success of our customers in nearly all sectors and almost every country in the world. Our portfolio comprises, as core businesses, the segments Chemicals, Materials, Industrial Solutions, and Nutrition & Care; our standalone businesses are bundled in the segments Surface Technologies and Agricultural Solutions. BASF generated sales of €65.3 billion in 2024. BASF shares are traded on the stock exchange in Frankfurt (BAS) and as American Depositary Receipts (BASFY) in the United States. Further information at www.basf.com.

Media Contact:

Dr. Ulla Biernat
ulla.biernat@basf.com
www.plastics.basf.com

SOURCE: BASF SE