Summary This paper addresses the effects of critical parameters that affect the performance and lifespan of proton exchange membrane (PEM) fuel cells. Amongst all, control of excess water content and dehydration in PEM fuel cells is the major issue under various operating conditions. Therefore, their effects on cathode, anode, gas diffusion layer (GDL), catalyst layer (CL), and flow channels are summarized in the initial part of this paper. Various active cooling strategies such as air cooling, liquid cooling, and phase change method to extract the waste heat from the stack are represented. The lateral part of this paper throws light on the role of heat pipes, working fluid, and the effect of the addition of nanofluid with pertinent filling ratio (FR) in cooling of PEM fuel cells. This work is intended to aid the selection of cooling methods for PEM fuel cells through the consideration of the variety of affecting parameters preceding major expenditure for wide‐scale production. In future, cost comparison associated with the cooling techniques of the fuel cell would be evaluated.

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This study highlights the thermal characterization of ABS-Graphene blended three dimensional (3D) printed functional prototypes by fused deposition modeling (FDM) process. These functional prototypes have some applications as electro-chemical energy storage devices (EESD). Initially, the suitability of ABS-Graphene composite material for FDM applications has been examined by melt flow index (MFI) test. After establishing MFI, the feedstock filament for FDM has been prepared by an extrusion process. The fabricated filament has been used for printing 3D functional prototypes for printing of in-house EESD. The differential scanning calorimeter (DSC) analysis was conducted to understand the effect on glass transition temperature with the inclusion of Graphene (Gr) particles. It has been observed that the reinforced Gr particles act as a thermal reservoir (sink) and enhances its thermal/electrical conductivity. Also, FT-IR spectra realized the structural changes with the inclusion of Gr in ABS matrix. The results are supported by scanning electron microscopy (SEM) based micrographs for understanding the morphological changes.