Manufacturing methods for metallic bipolar plates for polymer electrolyte membrane fuel cell

The bipolar plate (BP) is one of the main drivers of the polymer electrolyte membrane fuel cell (PEMFC) stack cost, and must also perform some critical functions simultaneously within the stack to ensure the required level of overall performance and durability. Therefore, the choice of material and production method for BPs that will meet the requirements for commercial BPs is crucial in PEMFC development. Compared to other material options such as graphite and composites, metals are more promising for the production of durable, thin, light, and low-cost BPs. However, there is still a need to reduce their processing cost through the development of cost-effective and mass production-friendly forming techniques that will not jeopardize the performance and durability of the formed plates. This paper discusses the various currently available fabrication methods for metallic BPs, with attention to their potentials for mass production and capabilities to produce plates that meet the performance and cost targets of commercial PEMFC BPs. In prospects of development drivers going forward, the potentials of hydroforming to outperform stamping for mass production of low-cost metallic plates are discussed. Current limitations facing high-quality metallic BP production and research trends are also highlighted.