Metal Etched Bipolar Plate for PEM Fuel Cell and Electrolyzer
Flow field Plate Overviews
Our etched flow field plates are engineered for high-performance hydrogen fuel cells and PEM electrolyzers. Manufactured using advanced photochemical machining (PCM) technology, these plates deliver exceptional flow channel precision, ultra-thin profiles, and outstanding corrosion resistance — ensuring reliable long-term operation in demanding electrochemical environments.
Xinhaisen manufactures precision etched bipolar plates using photo chemical etching for PEM fuel cells, PEM electrolyzers and hydrogen energy systems. Custom metal flow field plates can be produced with complex channels, holes, manifolds and other precision features according to customer drawings.
Key Features
| Fine Flow Channel Design |
Optimized channel geometry (0.2–1.0mm width) ensures uniform gas distribution and efficient water management |
| Ultra-Thin Etching (0.1mm+) |
Reduced stack height and weight, enabling compact and lightweight fuel cell designs |
| Long-Life Corrosion Resistance |
316L stainless steel and titanium alloy options withstand acidic PEM environments, passing ASTM G48 corrosion testing |
| High Precision (±0.01mm) |
Photochemical etching guarantees consistent channel depth and width across the entire plate surface |
| Burr-Free & Stress-Free |
Non-contact chemical etching eliminates mechanical stress, burrs, and micro-cracks |
- Custom flow field design
- Precision etched channels
- Fine holes and openings
- Burr-free or low-burr etched edges
- No mechanical cutting stress
- Suitable for thin metal sheets
- Repeatable production
- Prototype and mass production capability
- Custom dimensions and tolerances
- Multiple metal material options
Available Flow Field Patterns
- Parallel Flow Field
- Serpentine Flow Field
- Interdigitated Flow Field
- Pin-Type Flow Field
- Spiral Flow Field
- Multi-Pass Flow Field
- Customized Flow Channel Design
Manufacturing Capability
Our precision etching process enables the production of microchannels with excellent consistency while avoiding thermal distortion or mechanical stress.
Typical capabilities include:
- Fine channel structures
- Smooth channel walls
- Tight dimensional tolerances
- Complex internal geometries
- Large production capacity
- Consistent quality control
What is Chemical Etching?
Chemical etching (also known as photochemical machining) is a subtractive manufacturing process that uses chemical solutions to dissolve metal precisely. Unlike traditional stamping or machining, etching creates burr-free, stress-free plates without mechanical force. This allows for complex micro-flow channel designs, tight tolerances, and rapid prototyping, making it ideal for the intricate structures required in bipolar plates.
Product Specifications
| Parameter |
Specification |
| Product Name |
Etched bipolar Plate |
| Material Options |
Stainless Steel (304, 316L), Titanium, Copper, Alloy |
| Material Thickness |
0.02 mm – 1.5 mm |
| Min. Line Width |
0.015 mm |
| Min. Aperture (Hole) |
0.03 mm |
| Dimensional Tolerance |
±0.03 mm (Uniformity) |
| Lead Time |
Fast prototyping (5-7 days); Mass production available |
| Surface Finish |
As etched, passivated, or custom surface treatment |
Note: Custom specifications are available upon request.
Our Advantages
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Rapid Turnaround: With an efficient production setup, we handle urgent orders and large-volume demands without compromising quality.
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Cost Efficiency: Our chemical etching process eliminates high tooling costs (no expensive hard tooling required), making it cost-effective for both prototyping and mass production.
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Expertise in Thin Metals: Specializing in thicknesses down to 0.5mm, we offer solutions for lightweight stack designs that maximize energy density.
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Quality Assurance: We ensure high uniformity across thousands of pieces, critical for stable stack performance.
Applications
Bipolar plates manufactured by Xinhaisen are suitable for:
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Proton Exchange Membrane Fuel Cells (PEMFC): Used in automotive (cars, trucks), drones, and stationary power systems.
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Water Electrolyzers: For green hydrogen production.
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Portable Power Systems: Compact, high-efficiency energy devices.
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Aerospace & Aviation: Lightweight components for air mobility.
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- PEM fuel cells
- PEM electrolyzers
- Hydrogen electrolyzer stacks
- Fuel cell stacks
- Hydrogen energy systems
- Water electrolysis systems
- Laboratory fuel cell systems
- Electrochemical testing equipment
- Customized electrochemical flow field applications
FAQ
- Q: What materials do you recommend for bipolar plates?
A: We typically recommend Stainless Steel (316L) for its excellent corrosion resistance and cost-effectiveness, or Titanium for applications requiring higher strength-to-weight ratios.
- Q: Can you achieve the tight tolerances required for sealing?
A: Yes. Our etching process maintains a uniformity of ±0.01mm, ensuring that the plates mate perfectly with gaskets to prevent gas leakage.
- Q: Do you charge high tooling fees for custom designs?
A: No. One of the major benefits of chemical etching is the low tooling cost. We use digital tooling, allowing us to adjust flow field designs quickly without expensive physical molds.
- Q: What is the lead time for a prototype?
A: Typically, prototypes can be delivered within 5 to 7 days after design confirmation.
- Q: Can you handle large-scale production?
A: Absolutely. We are equipped to handle massive, high-volume orders while maintaining strict consistency across all plates.
Customization & OEM Services
We fully support custom flow channel patterns, plate dimensions, and material selection tailored to your specific fuel cell stack design. Simply provide your CAD drawing or design specifications, and our engineering team will deliver optimized etching solutions within 7–15 working days.
Contact us today to discuss your flow field plate requirements and receive a competitive quotation.
Welcome to contact us at any time!
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