Canadian fuel cell specialist Ballard Power Systems has outlined how it plans to scale next-generation bipolar plate production and reduce costs in the process. Bipolar plates are the second largest cost factor in FC stacks after membrane electrode assemblies (MEA).
Ballard aims to introduce the next generation of bipolar plates by the end of 2025 and expects the implementation of the project – including new manufacturing processes and new, cheaper material suppliers – to result in cost savings of up to 70 per cent. Ballard says that its thin and flexible graphite bipolar plates require significantly fewer materials while still ensuring stacks with high power density, according to Ballard. Graphite Lid
Beyond production cost savings, the project is expected to increase Ballard’s output by about ten times and shorten production cycle times. The manufacturer is not being more specific at this point, stating only that it has developed several new manufacturing processes that will enable full automation of the bipolar plate production process.
The Canadian company says it will set aside investment funds of about 18 million US dollars for the production of bipolar plates between 2023 and 2025. Ballard sees the next logical extension after the successful development of next-generation thin, flexible graphite bipolar plates and the expansion of membrane electrode assembly (MEA) manufacturing capacity in Canada as part of the company’s “3 by 3” programme.
“We’re thrilled to announce a project that delivers economic and environmental value for Ballard. Not only will we be able to reduce the cost of our bipolar plates and improve customer economics, but we will also consume far less energy, water, and material resources in the process,” said Mark Biznek, Ballard’s Chief Operating Officer. “This investment proves Ballard’s innovation in manufacturing technology, in addition to our demonstrated excellence in fuel cell technology innovation and commitment to ESG initiatives.”
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