Germany Copper Etching Micro Channel Fuel Cell Bipolar Plates Manufacturer

What Are Bipolar Plates?

Bipolar plates are one of the core components in hydrogen fuel cell systems. They serve multiple critical functions, including electrical current collection, uniform distribution of reactant gases, and effective heat and water management within the fuel cell stack.

As a key structural and functional element, bipolar plates directly influence the overall efficiency, durability, and operational stability of the fuel cell. They are widely used in applications such as automotive fuel cells, stationary power systems, aerospace technologies, and portable energy devices.

High-performance bipolar plates require precise design, suitable materials, and advanced manufacturing processes, making them a vital factor in the continued development and commercialization of hydrogen energy technologies.

Advantages of Etched Metallic Bipolar Plates

• High conductivity for efficient power output and heat dissipation

• Ultra-thin design enables compact stacks and higher power density

• Strong and durable, resistant to vibration, pressure, and thermal cycling

• Precision-manufactured flow channels for optimal gas and water management

• Scalable for mass production, ideal for automotive and energy systems

Application of Etched Metallic Bipolar Plates

1. PEMFC mass production
2. PEM/AEM electrolyser
3. High-temperature fuel cell
4. Lightweight design
5. Research and development and experimentation

What Material of Bipolar Plates We Produce?

Stainless Steel (316 / 316L)

Titanium & Titanium Alloy (Gr1,Gr2,Gr5)

Nickel (Ni200 / Ni201) & Nickel Alloys (Inconel,Hastelloy)

Copper & Copper Alloys

Aluminum & Aluminum Alloys (1060,3003,5052)

The Photo Chemical Etching Process for Bipolar Plates

1. Material Selection and Surface Preparation

Thin metal sheets such as 316L stainless steel, titanium, nickel, or nickel-based alloys are selected based on corrosion resistance, conductivity, and application requirements. The material is thoroughly degreased and chemically cleaned to ensure optimal photoresist adhesion and uniform etching.

2. Photoresist Coating

A light-sensitive photoresist is uniformly applied to one or both sides of the metal sheet using lamination or spin-coating. The coated sheet is then dried under controlled conditions to achieve consistent resist thickness.

3. UV Exposure and Pattern Transfer

A high-resolution photomask containing the designed flow field geometry is precisely aligned with the metal sheet. UV light exposure transfers the flow channel pattern onto the photoresist, defining the areas to be etched.

4. Developing

After exposure, the sheet undergoes a developing process that removes the exposed (or unexposed, depending on resist type) photoresist, leaving a precise resist pattern that protects the non-etched areas.

5. Chemical Etching

The patterned metal is passed through a controlled chemical etching system, where the exposed areas are selectively dissolved using a suitable etchant. Etching parameters such as temperature, concentration, spray pressure, and time are strictly controlled to achieve accurate channel depth, width, and profile.

6. Resist Stripping and Cleaning

Once the desired etch depth is reached, the remaining photoresist is stripped, and the bipolar plate is thoroughly cleaned to remove chemical residues, ensuring a smooth and contamination-free surface.

7. Secondary Processes (Optional)

Depending on design requirements, additional processes may be applied, including:

• Double-sided etching for complex flow fields

• Diffusion bonding or laser welding for plate stacking

• Surface treatments such as gold plating, carbon coating, or conductive anti-corrosion coatings

8. Inspection and Quality Control

Final inspection includes dimensional measurement, flow channel consistency checks, flatness testing, and surface quality evaluation to ensure compliance with customer specifications and fuel cell performance requirements.

This precision, non-mechanical process enables high-resolution micro-flow channels, excellent repeatability, and stress-free manufacturing, making photo chemical etching ideal for advanced metallic bipolar plates in fuel cells and electrolyzers.

Why Choose Us?

• Precision Photo Chemical Etching for complex, burr-free bipolar plate flow fields

• Multiple Metal Options including stainless steel, titanium, nickel, and specialty alloys

• Ultra-Thin & High-Accuracy Manufacturing for compact stacks and high power density

• Fast Prototyping to Mass Production with flexible, fully customized solutions

• Strict Quality Control ensuring consistent performance and long service life

FAQ:

1.What is the price of bipolar plate customization?

 -- The price will be depended on material, thickness, size and other requirements, please feel free to send us your detail requirements, we’ll offer you the price             asap.

2. How do we custom the bipolar plate?

 -- Please send us your drawing in DXF, DWG, STP, PDF and other formats, we’ll do the evaluation and offer you the price.

3. How can we guarantee quality?

 -- We always a pre-production sample before mass production, and always 100% final Inspection before shipment.

4. Why should you buy from us not from other suppliers?

 -- Xinhaisen is established to specialized in the production of high-quality, finite and micro-size photo chemical etching metal products.Our seventy professional             staff specialized in research and development , manufacturing and marketing service.

5. What services can we provide?

 -- Accepted Delivery Terms: FOB, CFR, CIF, EXW；

   Accepted Payment Currency:USD, EUR, JPY, CAD, AUD, HKD, CNY;

   Accepted Payment Type: T/T, Paypal, Western Union, Cash.

Do you want to custom the bipolar plate?   

Click "contact us" below to send us the drawing of Bipolar plate, we support DXF, DWG, STEP etc. Format.

Or send email directly at bella.xiang@xinhsen.com  /  WhatsApp: +86 18025476918