Chemical Etched Metallic Bipolar Plates With Perfect Flatness for Fuel Cell Stacking

Overview

Xinhaisen specializes in high-precision chemical etching of metallic bipolar plates. Using advanced photochemical machining (PCM), we produce burr-free, stress-free bipolar plates for proton exchange membrane fuel cells (PEMFC), solid oxide fuel cells (SOFC), and PEM electrolyzers. Our process ensures ultra-flat channels, tight tolerances, and rapid prototyping to mass production.

Product Features

• Ultra-high precision channels – Minimum line/space width down to 0.015mm; flow field depth uniformity within ±0.05mm

• Micro-hole capability – Coolant/distribution holes as small as 0.03mm diameter

• Thickness range – From 0.5mm to 3.0mm (thin foils for lightweight stacks or thicker plates for rigid designs)

• Material versatility – Stainless steel (304, 316L, 430), titanium (Grade 1/2), nickel-based alloys (Inconel, Hastelloy), copper, and other conductive/corrosion-resistant metals

• Burr-free & stress-free – No mechanical deformation, no micro-cracks, perfect for gasket sealing and membrane contact

• Cost-effective for medium-to-large volumes – Rapid turnaround on prototypes and high-volume orders

Technical Specifications

Typical Bipolar Plate Designs We Produce

• Anode & cathode flow field plates – Parallel, interdigitated, pin-type, or custom patterns

• Cooling plates – Internal cooling channel structures for thermal management

• Single plates & bonded pairs – Etched on one or both sides; alignment features for lamination/welding

• Perimeter sealing grooves – Integrated grooves for O-rings or laser welding

• Manifold/distribution holes – Uniform arrays for reactant/coolant distribution

Why Choose Etching for Bipolar Plates?

• Lower cost than CNC milling (especially for thin metals and fine channels)

• Shorter lead time – No hard tooling wear; design changes via phototool only

• No heat-affected zones – Preserves material conductivity and corrosion resistance

• Scalable – From 10 pieces (R&D) to 500,000+ pieces/month

Quality Assurance

• Inspection – 2.5D/3D measuring microscope, CMM, surface roughness tester

• Standards – ISO 9001:2015 certified processes

• Traceability – Full material certification (mill test reports available)

Industries Served

• Hydrogen fuel cell stacks (automotive, stationary power)

• PEM electrolyzers (green hydrogen production)

• Aerospace & UAV power systems

• Metal-air batteries

• Custom electrochemical cells

FAQ

• Q: Can you etch bipolar plates for fuel cells or electrolyzers?
  A: Yes, we specialize in precision etching of bipolar plates for fuel cells, electrolyzers, and other energy applications using metals like stainless steel and titanium.
• Q: What thickness of metal can you etch for bipolar plates?
  A: We can etch bipolar plates from 0.5mm to 3.0mm thick, with high precision and consistent channel depth.
• Q: How precise are the flow channels on your bipolar plates?
  A: Our etched flow channels achieve uniformity within ±0.05mm, and we can create micro-channels with line widths as fine as 0.015mm.
• Q: Can you produce both anode and cathode sides of a bipolar plate?
  A: Yes, we can etch both sides of a bipolar plate simultaneously or separately, depending on your design requirements.
• Q: What materials do you use for bipolar plate etching?
  A: We work with a range of corrosion-resistant metals including 304, 316L stainless steel, titanium, and nickel-based alloys.
• Q: Do you support low-volume prototyping or only mass production?
  A: We support both — from small R&D batches to large-volume production, with fast turnaround and no tooling costs.

Welcome to contact us at any time!