Laser-enhanced hollow embossing of metallic bipolar plates
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Funded by: Europäische Fonds für regionale Entwicklung (EFRE/JTF – Technologieförderung)
Project duration: 01.10.2025 - 31.12.2027
The energy transition is one of the key challenges in Germany and around the world. In this context, demand for hydrogen-based energy is continuously increasing. In order to meet this demand, there must be sufficient availability of electrolysers and fuel cells.
In order to achieve this, production capacities must be increased and manufacturing costs must be significantly reduced. Bipolar plates account for around 55% of material costs and approximately 28% of manufacturing costs, making them a major cost factor.
This is where the Hzwo: BiPWalz project comes in. The project's objective is to develop an innovative manufacturing approach that improves both resource efficiency and process performance. The production of bipolar plates is characterized by stringent dimensional and shape tolerance requirements, combined with high target cycle rates and minimal costs.
Currently, metallic bipolar plates are primarily manufactured using internal high-pressure forming, a method that only allows for low production rates. Conventional hollow embossing enables higher output volumes, but currently requires further development to meet the necessary tolerance accuracy.
Within the framework of the project "Hzwo: BiPWalz", a novel forming process is therefore being developed that meets high quality requirements, enables cost-effective mass production, and is designed as a continuous process suitable for industrial application.
To ensure the required shape tolerances, the base material is locally heat-treated using a laser source prior to the forming process. This enables the material properties to be adapted specifically to the stresses that occur during forming.
Collaboration partners:
- Sächsische Walzengravur GmbH
- Grötschel GmbH
- Professur für Formgebende Fertigungsverfahren (TU Dresden)
Associated partners:
- SITEC Industrietechnologie GmbH
- Profiroll Technologies GmbH
- ALF (TU Chemnitz)
Contact:
© Caroline Wierling
Ms Caroline Wierling
Dipl.-Ing.
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