Faraday Technology, Inc., in collaboration with Massachusetts Institute of Technology (MIT), is developing a novel electrochemical process that incorporates their previously developed gas diffusion electrode (GDE) technology and utilizes carbon dioxide (CO₂), captured from coal-fired power plant flue gas, to produce formic acid, a valuable chemical. In Phase I, tin GDE electrocatalysts were prepared by pulsed electrodeposition methods using Faraday Technology, Inc.’s low-cost technique, FARADAYIC® ElectroDeposition. Testing of the electrocatalytic performance showed that the best catalysts supported total current densities above 320 mA/cm², more than 50 percent greater than the highest values reported in the literatrue, and at formate selectivities competititve with those literature results (greater than or equal to 75 percent). In Phase II, tin electrocatalysts will be fabricated with novel microstructures enabled by pulsed-waveform electrodeposition. The electrocatalysts will be characterized and integrated into state-of-the-art flow electroreactors to test the electrocatalytic converion of CO₂ to formic acid. Techno-economic and scale-up/commercialization analyses will also be performed.