Custom Stainless Steel & Titanium Bipolar Plates With Micro-Etched Flow Channels for the US Market

Bipolar Plates Overview

Bipolar Plates are critical core parts in fuel cells and electrolyzers, serving as multifunctional elements that distribute reaction gases, collect and conduct current, manage water and heat, and provide structural support. At Xinhaisen, we specialize in manufacturing high-precision, corrosion-resistant metallic bipolar plates using advanced chemical etching technology. Our process ensures exceptional consistency, complex flow field patterns, and rapid production scalability to meet the demanding requirements of next-generation energy applications.

Manufacturing Process

Our bipolar plates are produced through a highly controlled precision chemical etching process:

• Material Selection & Cleaning: Choice of high-quality, corrosion-resistant metal alloys followed by thorough degreasing and surface preparation.

• Photoresist Coating & Patterning: Application of a photosensitive film. The designed flow field pattern is precisely transferred via UV exposure through a photomask.

• Precision Chemical Etching: The exposed areas are etched away in a controlled etchant bath, forming the intricate gas flow channels, coolant paths, and structural features with high accuracy.

• Stripping & Cleaning: Removal of the remaining photoresist and post-etch cleaning to ensure surface purity.

• Surface Treatment: Application of specialized coatings (e.g., for enhanced corrosion resistance or electrical conductivity) as per customer specifications.

• Dimensional & Quality Inspection: Rigorous verification of channel dimensions, depth uniformity, flatness, and overall tolerances using precision measuring equipment.

Bipolar Plates Features

• Ultra-High Precision & Complexity: Achieves intricate, fine, and multi-depth flow field designs impossible with traditional stamping, including micro-channels and hybrid patterns.

• Superior Uniformity & Consistency: Ensures uniform channel depth and geometry across the entire plate and from plate to plate, critical for stack performance.

• Burr-Free & Stress-Free: Chemical etching produces smooth channel walls without mechanical burrs, residual stress, or material deformation.

• Material Versatility: Capable of processing various grades of stainless steel, titanium, copper, and other specialized alloys.

• Rapid Prototyping & Scalability: Ideal for quick design iterations and seamless transition from prototype to high-volume production without expensive tooling changes.

• Design Flexibility: Easy and cost-effective implementation of design changes to the flow field pattern.

Bipolar Plates Specification

Bipolar Plates Applications

• Proton Exchange Membrane Fuel Cells (PEMFC): For automotive, stationary power, and portable devices.

• Electrolyzers (PEM & AEM): For green hydrogen production.

• Redox Flow Batteries: As electrode plates or current collectors.

• Cooling Plates: For advanced liquid cooling in high-power electronics and battery thermal management systems.

Our Advantages

• Precision & Speed: Unmatched expertise in high-tolerance etching (down to ±0.03mm uniformity) combined with fast material sourcing and agile production.

• High-Volume Capacity: Reliably fulfills both urgent, small-batch R&D orders and large-scale production demands.

• End-to-End Control: Integrated management from raw material procurement to final inspection ensures consistent quality and traceability.

• Proven Industry Reputation: Recognized by clients in demanding sectors (medical, aerospace, optics) for high quality, reliability, and technical partnership.

• Comprehensive Material Expertise: Deep experience etching a vast array of metals, enabling optimal material recommendations for your application.

FAQ

Q1: What are the main advantages of etched bipolar plates over stamped plates?
A: Etched plates offer superior design flexibility for complex, multi-depth flow fields, have no burrs or work-hardening effects, ensure excellent uniformity, and require no hard tooling, making them cost-effective for prototypes and design iterations.

Q2: What metals do you recommend for PEMFC bipolar plates?
A: 316L stainless steel is common for its balance of corrosion resistance and cost. We also process titanium (superior corrosion resistance) and can apply specialized conductive coatings per your performance requirements.

Q3: Can you produce plates with active coatings?
A: Yes. We provide plates ready for coating or can collaborate with coating partners. We ensure the base plate geometry and surface preparation are optimal for subsequent coating adhesion and performance.

Q4: What is your lead time for prototype samples?
A: For standard materials and validated designs, prototype samples can typically be delivered within 5-7 working days after design confirmation.