Etched Fuel Cell Bipolar Plates

Elcon Precision

Burr-free & stress-free process
Increased design flexibility and complexity with no incremental cost
Different designs can be etched on each side of plate
Channel accuracy to ±0.020 mm
Multiple channel depths can be routinely achieved
Dimensional repeatability
Volumes from rapid prototyping to full production.
Photochemically etched fuel cell bipolar plates

Etched fuel cell bipolar plates

Elcon offers bipolar flow field plates in a variety of metals with complex and precise liquid and gas flow channels.
The photo etching process is a subtractive method that removes metal from both sides of the plates simultaneously, so complex channels of different designs can be etched at the same time.
Unlike other processes, chemical etching imparts no mechanical or thermal stress on the plates, both of which can compromise stack bonding and fluid flow.
Quick, low-cost digital tooling: We use digital pattern tooling, which is low-cost, quick to produce and can be adapted easily to optimize designs. Because it is optically based, there is no incremental cost with increased design complexity or features.
To reduce cost and production time as well as meet design specifications, certain features such as channels can be photochemically etched, while others can be CNC machined in house. If plates need to be stacked together, we offer brazing and bonding services.
The geometric complexity and close tolerances offered by our photochemical etching process not only make it a desirable manufacturing method, but in some instances, the only technology suitable for fine featured designs.

Features

Removes metal from both sides of the plates simultaneously.
Burr-free & stress-free process ensures a flat and smooth surface for stacking.
Channel accuracy to ±0.020 mm.
Channels can have near vertical walls and flat bottoms with feature sizes determined only by material thickness.
Multiple etch levels can be achieved.
Low-cost digital tooling can be changed quickly and inexpensively to optimize designs.
Increased design flexibility and complexity with no incremental cost.
Dimensional repeatability.
Volumes from rapid prototyping to full production.

Simplified photochemical etching process

Applications

Hydrolyzers
Electrolyzers
Fuel cell plates

Contact us

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Elcon Precision Elcon Precision LLC, a precision component manufacturer with over 60 years of experience in photochemical etching, ceramic metallization, and brazed assemblies, produces photochemically machined bipolar plates for hydrogen fuel cells and electrolyzers. Elcon's photochemical etching process removes metal from both sides of aluminum, stainless steel, or titanium bipolar flow field plates simultaneously, creating burr-free, stress-free surfaces with channel accuracy to ±0.020 mm and no mechanical or thermal stress that could compromise stack bonding or fluid flow. The company's low-cost digital pattern tooling can be quickly and inexpensively adapted to optimize plate designs without incremental cost for increased complexity, supporting rapid prototyping through full production volumes for polymer electrolyte membrane (PEM) fuel cells. Elcon also produces compact alkaline water electrolyzers using photoetching techniques, applying thin conductive metal coatings like platinum and palladium to improve efficiency and durability, and supports both lithium-ion battery and hydrogen energy storage technology developers through prototype and production parts for fuel cell plates and battery grids.

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