Design of Experiments Guided Identification of Coupled Component Interactions in Cu Gas Diffusion Electrodes for Electrochemical CO 2 Reduction to Multi‐Carbon Products

ABSTRACT A Design of Experiments (DoE) approach is used in the design and development of gas diffusion electrodes (GDEs) for electrochemical CO 2 reduction (CO 2 R). Rational GDE design remains challenging due to the presence of multiple components and their complex effects on performance. Here, five electrode components, Cu, carbon, polytetrafluoroethylene, Nafion, and Sustainion, are evaluated for electrochemical CO 2 R using the DoE approach by evaluating 17 distinct single‐active‐layer (SAL)‐GDEs. Experimental results are analyzed using a definitive screen design (DSD) framework to identify component‐performance relationships, including first‐ and second‐order effects. Nafion is found to strongly affect overall product distribution, while carbon is most influential for improving C 2 H 4 selectivity. The DSD models are validated with experiments, enabling formulation predictions beyon…