The finite nature of fossil fuels and their adverse environmental impacts have intensified the demand for sustainable energy technologies. Among the most promising clean energy conversion systems are proton-exchange membrane fuel cells (PEMFCs); however, their widespread commercialization remains constrained by the sluggish oxygen reduction reaction (ORR) at the cathode. Carbon-supported platinum (Pt/C) remains the benchmark ORR electrocatalyst, while Pt alloys, high-entropy alloys (HEAs), intermetallic compounds, and crystal-phase-engineered catalysts have demonstrated improved catalytic activity and reduced precious metal loading. Despite these advances, conventional catalyst synthesis often relies on hazardous chemicals, energy-intensive processes, and generates substantial waste, creating a sustainability paradox [1,2]. Moreover, the translation of laboratory-scale synthesis methods into cost-effective, large-scale manufacturing remains a significant challenge. Therefore, the development of high-performance ORR electrocatalysts through sustainable, low-cost, and environmentally benign synthesis strategies is critical for the commercialization of next-generation PEMFCs. Green synthesis is not only environmentally advantageous but also essential for realizing truly sustainable fuel cell technologies [1–4].
This presentation highlights emerging green chemistry strategies and our recent research in the sustainable synthesis of PEMFC electrocatalysts. Particular emphasis will be placed on environmentally responsible approaches that employ water-based processing, minimize waste generation and energy consumption, and utilize renewable feedstocks, including biopolymers, biomimetic polymers, and designer polymers, as multifunctional platforms for engineering highly active ORR electrocatalysts [1,4–7]. The presentation will further explore how the convergence of sustainable synthesis, advanced materials engineering, computational modeling, machine learning, and data-driven materials discovery is transforming electrocatalyst development. By integrating these multidisciplinary approaches, it is becoming possible to accelerate the design of cost-effective, high-performance catalysts with enhanced activity, durability, and scalability. Such innovations not only address critical challenges in PEMFC commercialization but also align with global sustainability goals, paving the way for the next generation of environmentally responsible energy conversion technologies.