Gel-Encapsulated Fibre-Shaped Fuel Cells Bring Flexible Power to Wearables

Scientists have developed a new type of fibre-shaped direct methanol fuel cell that can be bent, cut, refueled in under a minute, and woven into textiles. Using a gel-mediated encapsulation system with cotton fibres, the cells deliver an energy density of 161.36 Wh/kg and withstand more than 2,000 flexing cycles—paving the way for next-generation wearable electronics.

Feng Yan at Donghua University has created fibre-shaped direct methanol fuel cells that overcome long-standing barriers of rigidity and fuel sealing in traditional systems. Their innovation lies in enclosing cotton fibres within a gel matrix that swells dynamically when in contact with methanol. This swelling both reinforces the internal structure and regulates fuel pressure, enabling a robust, flexible design.

The new cells achieve reliable performance across extreme temperatures—from –22 °C to 70 °C—while maintaining output after more than 2,000 continuous bending cycles. They also refuel in less than one minute at ambient conditions. At an energy density of 161.36 Wh/kg, the system surpasses typical fibre-based power technologies and rivals conventional portable batteries.

“It’s brilliant how they lean on everyday cotton and a savvy gel to tackle a tough engineering puzzle,” noted independent energy researcher Dr. Maya Patel, who praised the simple yet scalable approach.

This breakthrough could reshape how energy is integrated into smart textiles, medical monitors, defense gear, and remote sensors. Unlike rigid lithium-ion packs or bulky hydrogen fuel cells, the gel-encapsulated fibre format can be cut to size, embedded in garments, and topped up quickly without specialized equipment.

With methanol already produced and traded at scale worldwide, the technology aligns with existing infrastructure while avoiding the costs of high-pressure storage. Pilot testing for wearable applications is expected within the next two years, with potential consumer rollout before the next decade.

Innovative Flexible Fuel Cells for Wearables

Innovative Flexible Fuel Cells for Wearables - Fuelcellsworks