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Multi-Stage Roller Embossing of Bipolar Plate Microchannels Using 3D-Printed Tooling

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Abstract:

Bipolar plates are key components in fuel cells, and their performance strongly depends on the geometry of the microchannels used to distribute reactant gases. Producing channels with sufficient depth in thin metal sheets remains challenging, particularly when cost-effective manufacturing routes are required. This work investigates a multi-stage roller embossing process for forming bipolar plate channels using additively manufactured polymer tools. By dividing the total deformation into multiple forming stages, the process reduces tool deflection that typically limits channel depth in single-pass embossing. Experiments conducted on 0.1 mm stainless steel foil show that the multi-stage approach increases the achievable average channel depth from approximately 0.25 mm in a single pass to approximately 0.34 mm, resulting in a maximum aspect ratio (channel depth to width) of 0.314. These results indicate that combining multi-stage forming with 3D-printed tooling provides a practical route for flexible and low-cost fabrication of metallic bipolar plates, especially for low volume production.

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Periodical:

Solid State Phenomena (Volume 389)

Pages:

191-206

DOI:

https://doi.org/10.4028/p-Y78kVu

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Cite this paper

Online since:

April 2026

Authors:

Maziar Khademi*, Peng Neo Zhang, Michael P. Pereira, Matthias Weiss

Keywords:

3D Printed Tool, Bipolar Plates, Fuel Cell, Micro-Roller Embossing, Multi Stage Forming

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Creative Commons CC BY 4.0

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* - Corresponding Author

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