Fuel Cell Bipolar Plates

Bipolar Plates (BPPs) for fuel cells are at the heart of Hydrogen conversion into electric power. This green technology is now ready at Interplex, based on customized designs.

Hydrogen fuel cells represent an important enabling technology in the shift from fossil fuel energy generation to clean energy sources, finding its place in applications such as electric vehicles, transportation, energy storage and power generation. A critical factor in today’s advanced fuel cells is high-volume, high-quality production of the multiple BPPs at the heart of the energy generation process in the fuel cell system.

A Trusted Partner in Fuel Cell Solutions

Interplex is proud to embark on a journey to zero emissions with our valued customers. With our established expertise in producing metal BPPs for top-tier customers, we are well-positioned to deliver the industry’s demands today, and tackle those of tomorrow.

Our BPPs are a key component of Proton Exchange Membrane Fuel Cells (PEMFC). They distribute Hydrogen and air effectively and reliably, conduct electrical current from cell to cell and remove heat from the active area without leakage of gases or coolant.

Unique Selling Proposition

  • High-precision BPPs with integrated overmolded gasket
  • Multi-technology expertise: From tool and fixture design to high-precision forming processes, production optimization and more
  • Vertically integrated in-house capabilities – full ownership of an end-to-end solution, and quality you can trust
  • Improved fuel cell system performance and lifespan – high yield from stringent internal quality control and process expertise
  • Scalable technology and rapid ramp-up to high-volume production of millions of BPPs yearly
  • In-house tool design and manufacturing and FEA before design – quick turnaround time to develop prototype samples and build first test stack
  • Expansive global footprint – production in close proximity to customers

Markets Served

Types of Applications

  • Fuel cell vehicles (FCVs) including cars, trains and buses
  • Electric taxiing systems for civil aviation aircraft
  • Logistics vehicles including freight trucks, forklifts
  • Maritime vessels
  • Heating systems for buildings
  • Power generation

Fuel Cell BPP Features

Anatomy of a Fuel Cell BPP

Anode and Cathode Sheets

  • Material: SUS316L Stainless Steel or similar
  • Raw Material Thickness: 0.075 – 0.1mm
  • High-speed progressive stamping for high-volume production
  • State-of-the-art technology for minimum thinning, very fine structures and increased durability
  • PVD pre-coating/coating provides corrosion resistance and maintains low electrical contact resistance

Flow Channels (Key Parameters)

  • Channel height: ±0.015mm
  • Thickness evenness: ≤8% (active area)
  • Thickness thinned ratio:≤25%
  • Channel flat width: ±0.03mm
  • Channel pitch down to: 1.0mm

Welding Seam

  • High-precision welding
  • Automated material handling shortens cycle time for high-volume production
  • Stringent quality control processes, including 100% welding quality leakage test


  • Tight dimensional and positional tolerances achievable via high-precision overmolding
  • Material: Liquid silicon or EPDM rubber
  • Stringent quality control processes, including 100% seal quality leakage test
  • Even pressure distribution prevents leakage and prolongs lifespan