2025/06/27 by Asami, Mohammad Karim, Roth, Sebastian, Hünting, Jan +2
#Electronic Engineering #Technology::620: Engineering::620.1: Engineering Mechanics and Materials Science #Technology::621: Applied Physics::621.3: Electrical Engineering #additive manufacturing (AM) | bipolar plates | fuel cell (PEMFC) | electrolysis cell (PEMEC) | material extrusion of metals (MEX/M) | laser powder bed fusion of metals (PBF-LB/M) | prototyping #design for AM (DfAM)
paper · doi:10.15480/882.15300
Additive manufacturing (AM) technologies have witnessed remarkable advancements, offering opportunities to produce complex components across various industries. This paper explores the potential of AM for fabricating bipolar plates (BPPs) in fuel cell or electrolysis cell applications. BPPs play a critical role in the performance and efficiency of such cells, and conventional manufacturing methods often face limitations, particularly concerning the complexity and customization of geometries. The focus here lies in two specific AM methods: the laser powder bed fusion of metals (PBF-LB/M) and material extrusion of metals (MEX/M). PBF-LB/M, tailored for high-performance applications, enables the creation of highly complex geometries, albeit at increased costs. On the other hand, MEX/M excels in rapid prototyping, facilitating the swift production of diverse geometries for real-world testing. This approach can facilitate the evaluation of geometries suitable for mass production via sinter-based manufacturing processes. The geometric deviations of different BPPs were identified by evaluating 3D scans. The PBF-LB/M method is more suitable for small features, while the MEX/M method has lower deviations for geometrically less complex BPPs. Through this investigation, the limits of the capabilities of these AM methods became clear, knowledge that can potentially enhance the design and production of BPPs, revolutionizing the energy conversion and storage landscape and contributing to the design of additive manufacturing technologies.