Ballard, the fuel cell manufacturer, is implementing a plan to reduce the cost of new-generation bipolar plates, while increasing production capacities. Mass production is to start by the end of 2025.

The Canadian manufacturer has developed graphite bipolar plates using proprietary technology. Bipolar plates are the most expensive components after membrane assembly. The new generation of bipolar plates uses thin, flexible layers of graphite. This process considerably reduces the materials (45% reduction in raw materials) used for the plates, while enabling high power density stacks. This is an important factor, which is why these graphite bipolar plates are suitable for heavy mobility. They have: a longer lifespan, they can be reused at the end of the fuel cell’s life and they have a high power density (4 Kw/L), all of this at a lower cost.

Thanks to a new manufacturing process (automated and using less energy and water) and with the help of suppliers of new materials, Ballard is announcing a cost reduction of bipolar plates as high as 70%. Ballard is aiming to meet the US Department of Energy’s target of 5 dollars per kW for bipolar plates.

In addition to cheaper plates, the process will increase production capacity tenfold. The Canadian manufacturer will invest $18 million in this project.

Do you want to learn more about bipolar plates and Ballard? Then our latest 2 articles on the subject should interest you. You can read one about the company Ballard here and one about bipolar plates here. 

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Article written by Laurent Meillaud and translated by Logan King