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Rubber Forming as a Novel Manufacturing Approach for Bipolar Plates in Fuel Cell Systems

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Abstract:

Hydrogen-based energy systems are considered a key pillar of the energy transition, yet the cost-efficient, mass production of metallic bipolar plates (BPPs) for proton exchange membrane fuel cells (PEMFCs) remains challenging, as conventional processes are limited by comparatively long cycle times and forming-related instabilities. This paper investigates the rubber drawing process as a cost-efficient manufacturing method for metallic bipolar plates, proposed as an alternative to the commonly applied hydroforming process, analysing the influence of pressing force, rubber hardness and thickness, tool modifications for varying pressure distribution, and the suitability of additively manufactured tool dies made from Maraging Steel 1 (X3NiCoMoTi 18-9-5) or ceramic-filled UV resin. The results show that precise and stable tool guidance, as well as a well-adapted tool setup, are required to achieve reproducible component quality; targeted adjustments of process and rubber parameters improved channel dimensional accuracy, but revealed limited forming capability in certain areas. Furthermore, concavely and convexly modified rubber dies reduced component warping in specific directions, and steel dies exhibited higher precision and less distortion compared to ceramic-filled UV resin dies. These findings highlight the potential of the rubber drawing process for cost-effective production of bipolar plates, while identifying key parameters for further optimization toward industrial-scale manufacturing.

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Periodical:

Solid State Phenomena (Volume 389)

Pages:

227-241

DOI:

https://doi.org/10.4028/p-k4HkEk

Citation:

Cite this paper

Online since:

April 2026

Authors:

Bernd Arno Behrens, Sven Hübner, Simon Pauli, Henner Rüschkamp, Simon Kimmina, Denis Fink, Behdad Yaaalimadad*

Keywords:

Bipolar Plates, Fuel Cell Systems, Rubber Forming, Sheet Metal Forming

Funder:

The publication of this article was funded by the Leibniz Universität Hannover (LUH) / Technische Informationsbibliothek (TIB)

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Creative Commons CC BY 4.0

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* - Corresponding Author

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