Rapid Prototyping of PEM Fuel Cell Bi-Polar Plates using 3D Printing and Thermal Spray Deposition

This article presents the results of exploratory research on novel methods for the fabrication of functional, metallic, gas flow, bi polar plates (BPP) for use in proton exchange membrane fuel cells (PEMFC). Low cost, high speed, additive manufacturing methods that combine 3D printing (3DP) and thermal spray (TS) technologies are described. Functional flow plates were manufactured by creating 3DP patterns and then depositing, and releasing, dense metals with TS methods. The new method yields dense metal plates, with interesting options for material choices and complex designs.