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Bipolar Plates Manufacturing

SEN-HFC-DB-1 - Embossing Calender for Bipolar Plates

Matthews International GmbH

  • Embossing calender for metal and graphite bipolar plates
  • Very sturdy and compact design
  • High automation level

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Description Vendor

The Embossing Calender is designed for metal and graphite Bipolar Plates. It offers a very sturdy and compact design, direct drive of each roller, and high automation level. The machine supports both inline and offline applications, and features optional technologies such as electro-hydraulic control engineering, preheating systems, cutting units, and inspection systems. It can handle laser/milling widths up to 1950 mm with a maximum diameter of 500 mm. The calender operates by applying compression force up to 300 tons through rollers with diameters up to 1,000 mm, achieving gap accuracy of ±1 μm. It can also adjust roller temperatures between +10 °C and +200 °C. With its advanced capabilities, the Embossing Calender provides a one-stop-shop solution for precision embossing and surface processing.

Use Cases

  • Embossing and surface structuring of metal and graphite bipolar plates for fuel cell production. 

Capabilities

  • Performs high-precision embossing with gap accuracy of ±1 μm using roller-based compression. 
  • Applies compression forces up to 300 tons for forming bipolar plate structures. 
  • Supports roller temperature control from +10 °C to +200 °C for process optimization. 
  • Processes web materials up to 1,000 mm width at production speeds up to 150 m/min. 
Matthews International GmbH Matthews International Corporation (NASDAQ: MATW), a global provider of industrial technologies through its Matthews Engineering business (encompassing Saueressig Engineering, Terrella Energy Systems, and OLBRICH GmbH), has established a strong position in hydrogen fuel cell bipolar plate manufacturing following its 2021 acquisition of Terrella Energy Systems, Ltd. (a Vancouver, Canada-based leader in the design and manufacture of bipolar graphite plates for hydrogen fuel cell power systems, founded 2012). The company entered a two-year Joint Development Agreement with Illuming Power Inc. in February 2022 to develop an automated, expanded graphite bipolar plate production line combining Matthews Saueressig Engineering and Terrella Group's expertise in rotary embossing/cutting tools with Illuming Power's materials and bipolar plate design/stack functionality expertise, dramatically reducing production costs and accelerating mass market adoption of fuel cells for transportation and stationary applications. Matthews established a Hydrogen Fuel Cell (HFC) Development Center in Burlington, North Carolina in February 2024 (supported by a North Carolina Rural Infrastructure Authority grant), relocating bipolar plate manufacturing and prototyping operations under the Terrella Energy brand, with capabilities to fabricate flat die and rotary embossing tooling for graphite bipolar plates and a low-volume production line, strategically positioned within the Southern Automotive Corridor near EV automakers and battery manufacturers.
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