The transition from carbon-based economies to sustainable human development, is boosting renewable energy systems [
1]. Alongside the more traditional technologies for the valorization of renewable energy, like wind, solar, hydro-and geo-thermal and biomass, microbial fuel cells (MFCs) have gained great interest in recent years. MFCs are bio-electrochemical devices that combine a power production mechanism similar to that of traditional fuel cells, with biotechnological processes like water treatment [
2,
3], bioremediation [
4], and sensing [
5,
6,
7], thanks to the presence of electroactive bacteria at their anodes[
8,
9,
10,
11,
12]. These microorganisms can directly transduce the chemical energy, entrapped into organic matter, into electrical energy. Indeed, electroactive bacteria work as anodic biocatalysts in anaerobic conditions, oxidizing organic matter dissolved into the electrolyte and releasing the produced electrons to the anode. Electrons flow continuously to the cathode compartment where their re-combination with terminal electron acceptors (TEAs) is ensured. MFCs in open-air configuration use oxygen as the TEA. The target cathodic reaction is the direct oxygen reduction reaction (ORR). As demonstrated by several works in the literature [
13,
14,
15,
16,
17], ORR is the usual choice for the cathodic reaction as oxygen maximizes power production while allowing environmental application of MFCs. Catalysts are needed to promote the ORR according to the direct reduction of O
2 in water and to optimize the reaction kinetics. If properly catalyzed, the secondary reaction pathway of the ORR, associated to the production of toxic hydrogen peroxide, can be completely avoided. The best performing catalyst is platinum [
13,
14,
15,
16,
17]. Pt is applied at the surface of the cathode in such a way to ensure optimal contact with both the electrode itself and the electrolyte. The resulting interface is the most critical one for fuel cell technologies since it is associated to the triple-phase boundary, i.e. the zone where protons, electrons and oxygen molecules must reach the catalyst sites to react [
18,
19,
20,
21]. In this view the Gas Diffusion Layer (GDL) is a key component of fuel cells to manage diffusion of gaseous reactants, such as oxygen, to promote removal of excess water in proximity of the catalyst layer and, in MFCs, to minimize as much as possible the electrolyte leakage [
22]. The ideal GDLs must satisfy several properties, such as high gas diffusion [
23,
24], good bending stiffness, continuous porosity, air permeability, water vapor diffusion, high surface area to volume ratio to ensure the water removal, good electrical and electronic conductivity to ensure the proper electrons’ transfer and suitable mechanical stability [
21]. For what concerns air-cathode single chamber microbial fuel cells (a-SCMFCs), commonly used GDLs are characterized by a backbone made of a carbon-based material acting as the electrode, which is then covered by the catalyst layer on one side [
25], and by a hydrophobic coating, typically based on polytetrafluoroethylene (PTFE) on the side. PTFE is strongly hydrophobic and permeable to oxygen. These properties can be very useful to design GDLs for MFCs since this polymer can act as a barrier to avoid electrolyte leakage from the cell, while allowing oxygen diffusion, and contributing to avoid excess of water, so preventing the cathode flooding [
26,
27,
28,
29,
30]. Nevertheless, the PTFE layer needs careful design in order to avoid any negative influence to the final behavior of the cathode. Guerrini et al. [
30] demonstrated that excess PTFE in GDLs for open-air cathode MFCs, can make the electrode too hydrophobic preventing water from reaching the catalytic sites, inhibiting the ORR reaction. Moreover, many works in the literature, in the main fields of fuel cell technology, focused their attention on the GDLs’ structure, that could be a bottleneck for improving of functionality of this layer [
18,
19,
20,
21,
22,
23,
24,
25,
26,
27,
28,
29,
30]. Indeed, during last decades, nanostructured materials, gained increasing interest in the design of GDLs to overcome the above-described limitations, ensuring optimized gas diffusion, optimal water management and structural refinement [
18,
31,
32].
The present work proposes the development of a novel nanostructured-gas-diffusion-layer (nano-GDL) to improve the overall behavior of a-SCMFCs with the aim to obtain the best compromise among hydrophobicity and surface wettability properties of GDL. To overcome all the limitations associated to the unprecise use of PTFE, which can induce an incomplete wetting of the cathode electrode, novel nano-GDLs were prepared by the electrospinning process directly collecting on the same carbon-based electrode two different nanofiber mats. The electrohydrodynamic process promotes optimal interaction among the different layers, avoiding the need of a binder. The first layer (inner-layer) was made of cellulose nanofibers that play a crucial role to promote oxygen diffusion into SCMFC [
29,
30]. With the aim to improve the adhesion of this first nanostructured layer to the carbon backbone, in the present work, we propose to create carbonized patterns into the cellulose nanofibers by direct laser writing. To this purpose, the carbonized patterns were designed allowing the creation of graphene-like regions (i.e., Laser Induced Graphene) combined with un-treated cellulose nanofibers which played a key role ensuring the necessary hydrophilicity to improve water retention in proximity of the active catalytic sites, thus avoiding any decrease of proton conductivity of the electrolyte by dehydration [
29,
30]. The second layer (outward-layer) was based on polyvinyl-fluoride (PVDF) nanofibers with the main purpose to prevent the electrolyte leakage, while allowing oxygen free to flow combined with a correct water removal from cathode electrode.
The design of new nano-GDL allowed exploiting all nanofibers intrinsic properties, such as high surface ratio to volume, high continuous porosity, and light weight, achieving thus a good oxygen diffusion in the proximity of the catalyst layer, ensuring optimal surface wettability, and thus favoring the direct ORR while preventing the water flooding in correspondence of catalyst layer. We proposed the ideal catalyst layer for ORR, based onto Platinum on carbon [
35], directly deposited on the inner side of carbon paper, on which both of two nanostructured layers were directly collected. To investigate the good performances of SCMFCs, achieved when nano-GDLs were employed, cathode electrodes with commercial gas diffusion layers, made of PTFE, were used for comparison. We demonstrated the capability of a-SCMFCs with nano-GDLs to achieve a maximum current density equal to (132.2 ± 10.8) mA m
-2, an order of magnitude higher than the one reached with commercial-PTFE, equal to (58.5 ± 2.4) mA m
-2. To confirm the extremely/excellent performances, provided by nano-GDLs, we propose an analysis of obtained results in terms of energy recovery, as already reported in our previous work [
36]. In line with the trend obtained by analyzing the current densities, it is possible to state that nano-GDLs ensured the achievement of an energy recovery of 60.83 mJ m
-3, one order of magnitude higher than the value obtained by commercial-PTFE (3.92 mJ m
-3). All these latter results open the doors to the design of the whole nanostructured cathode electrode in SCMFCs. To achieve this goals, nitrogen-doped carbon nanofibers (N-CNFs) can be proposed as conductive carbon backbone, able to exploit simultaneously good electrocatalytic properties for ORR, as deeply defined in our previous work [
11].