Bipolar plates for the next generation of proton exchange membrane fuel cells (PEMFCs): A review of the latest processing methods for unconventional flow channels
The rapid, unsustainable depletion of finite fossil fuel resources and their environmental consequences demand the deployment of affordable clean and sustainable energy solutions. Polymer electrolyte membrane fuel cell (PEMFC) technology is an important pathway in decarbonization of modern energy systems, especially when fueled by high-purity green hydrogen. In PEMFCs, bipolar plates largely determine cell efficiency, longevity, and affordability, which in turn depends on both material selection and design of the embedded flow channels. Conventional manufacturing processes have long been used to fabricate standard bipolar plate designs; however, they are incompatible with unconventional, intricate geometries due to their insufficient resolution and precision in fabrication of fine features, and reliance on multi-step post-processing modifications that limit their design adaptability. This lack of design flexibility impedes the translation of innovative laboratory-scale concepts to industrial-scale production and their practical adoption. In recent years, a growing body of research publications and patent disclosures has reported advanced manufacturing methods, such as additive manufacturing, capable of producing intricate bipolar plate geometries at competitive costs. However, a discussion of these manufacturing approaches, along with an assessment of their scalability and industrial readiness, remains absent in the literature. This study aims to fill this gap. It outlines recent progress and proposes future research directions toward affordable and efficient bipolar plate solutions for advanced PEMFC systems.