Manufacturing Processes for Proton Exchange Membrane Fuel Cell Bipolar Plates

Proton exchange membrane fuel cell bipolar plates serve as both current collectors and gas distributors within a fuel cell stack. Manufacturing methods for metallic bipolar plates have evolved rapidly to meet demands for high throughput, precise channel geometry and cost reduction. Traditional graphite plates, while chemically stable, suffer from brittleness and machining expense. In contrast, stainless steel and nickel alloys offer superior mechanical strength, electrical conductivity and compatibility with high-volume forming techniques. Key processes include stamping and micro-stamping, hydroforming, roll forming and additive manufacturing. Stamping methods rely on rigid dies to imprint flow channels but require careful tool design to avoid defects such as wrinkling and thinning. Hydroforming uses pressurised fluid to shape sheets within a closed die, enabling smooth channel surfaces and reduced springback. Hollow embossing rolling affords continuous production of plates by feeding sheet between patterned rollers, offering rapid cycle times once process parameters are optimised. Powder bed fusion 3D printing extends capability to complex channel architectures, though it demands control over thermal distortion and surface finish. Across all methods, finite element modelling guides tool geometry, support strategies and material selection to balance formability, structural integrity and mass production requirements. Surface coatings and post-forming treatments are often applied to improve corrosion resistance and interfacial contact resistance. The global push towards net-zero emissions has heightened interest in scalable, low-cost bipolar plate production, with current efforts focusing on reducing tool wear, minimising energy consumption and integrating real-time quality control.

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Manufacturing Processes for Proton Exchange Membrane Fuel Cell Bipolar Plates publication trend

The graph below shows the total number of articles in manufacturing processes for proton exchange membrane fuel cell bipolar plates across all publications each year (not limited to Nature Index journals).

Technical terms

Bipolar plate: A conductive separator that channels reactant gases and collects current in a fuel cell stack.

Proton exchange membrane fuel cell (PEMFC): A device converting chemical energy to electricity through electrochemical reactions at low temperatures.

Hydroforming: A metal forming process using fluid pressure to shape sheets within a closed die cavity.

Hollow embossing rolling: A continuous process in which sheet metal passes through patterned rollers to form channel geometries.

Powder bed fusion: An additive manufacturing technique that selectively melts metal powder layers with a heat source to build 3D parts.

Wrinkling: A deformation defect in sheet forming characterised by out-of-plane buckles due to compressive stresses.

Springback: The elastic recovery of a metal sheet after forming, causing dimensional deviation from the die shape.

Finite element model (FEM): A numerical simulation method for predicting stress, strain and deformation in forming processes.

References

1. Model validation of hollow embossing rolling for bipolar plate forming. International Journal of Material Forming (2024).
2. Study on Springback Behavior in Hydroforming of Micro Channels for a Metal Bipolar Plate. Materials (2024).
3. Powder Bed Fusion 3D Printing and Performance of Stainless-Steel Bipolar Plate with Rectangular Microchannels and Microribs. Energies (2022).