From Lab to Fab: Path Forward for Multi-Scale Design of Industrial Anion Exchange Membrane Electrolyzers.

Anion exchange membrane water electrolysis (AEMWE) has emerged as a pivotal pathway bridging laboratory-scale research to large-scale hydrogen production. Nevertheless, its commercialization is constrained by multi-scale failure mechanisms that operate across scales ranging from atoms to entire systems, including catalyst dissolution and reconstruction, degradation of the three-phase interface with membrane electrode assemblies, corrosion of bipolar plates, and uneven stack assembly. This review systematically investigates the failure behaviors of AEM electrolyzers across multiple scales and introduces a collaborative design strategy spanning from the atomic to the system level. By integrating innovative membrane-electrode architectures, biomimetic flow-field designs, and advanced intelligent control systems, we establish a full-chain optimization scheme spanning materials, devices, and systems that simultaneously improves current density, durability, and dynamic response. Emphasizing the critical roles of in situ characterization and artificial intelligence in elucidating failure mechanisms and enabling predictive control. This review also provides a systematic multi-scale design blueprint and a technical pathway for transitioning AEMWE from laboratory-scale prototypes ("Lab") to gigawatt-scale fabrication facilities ("Fab"). Ultimately, it aims to facilitate the adoption of AEMWE as an efficient and reliable industrial solution for the green hydrogen economy.