In the research field of CO2 electroreduction, gas diffusion electrodes (GDEs) are predominantly manufactured through solvent-based processes. Meanwhile, the solvent-free method has gained heightened attention due to its potential to reduce operational and production expenses, while considering ecological aspects such as solvent evaporation, circulation, and waste treatment. Drawing from its successful applications in other fields, we have specifically developed a solvent-free manufacturing method to produce multi-layered Cu-based GDEs for CO2 electroreduction. The procedure is compatible with industrial production lines, specifically through a roll-to-roll process. By evaluating the interplay between production parameters and electrochemical performance of GDEs via various characterization methods, key factors, i.e., hydrophobicity, gas permeability, thickness, and pore size, were adjusted and applied to achieve a highly selective GDE towards C2+ products (alcohols and ethylene) at industrial relevant currents up to 300 mA cm−2 (ethylene ∼40%, ethanol ∼10%, n-propanol ∼15%).
