Interface – Microstructured Bipolar Plates for Greater Power Density and Service Life

The aim of the research project Interface – Optimisation of the BPP/GDL interface and improvement of water management to increase the power density and service life of PEMFCs is to increase the power density of polymer electrolyte fuel cells (PEMFCs) by up to 30% and significantly extend their service life through targeted laser-based microstructuring of bipolar plates (BPP) to increase the power density of polymer electrolyte fuel cells (PEMBZ) by up to 30% and significantly extend their service life. To this end, the The Hydrogen and Fuel Cell Center (ZBT) and the Fraunhofer Institute for Laser Technology (ILT) are developing new processes for surface modification on a micrometer scale.

A particular focus is on optimising the interface between the BPP and the gas diffusion layer (GDL) in order to improve the removal of liquid water from the reaction zones and reduce electrical contact resistance. This addresses two key obstacles to efficiency losses and premature ageing of PEMFCs. Using high-resolution X-ray microscopy, the water distribution in the cell structure is being made visible in operando for the first time and correlated with performance data.

The research results will enable manufacturers of fuel cell components – especially small and medium-sized enterprises (SMEs) – to make targeted improvements in the development, production and quality assurance of BPPs and GDLs. Companies in the fields of laser technology, surface finishing and sensor technology can also benefit directly from the structures and test protocols developed.

The project started on 1 July 2025 and will run for 30 months.

Interface is funded by the German Federal Ministry for Economic Affairs and Climate Protection (BMWK) as part of the Industrial Collective Research (IGF) programme via the AiF.

XRM-Aufnahmen: Dummy-Zelle mit Wasser in Kanälen (l.), Querschnitt durch MEA und BPP der Dummy Zelle mit Wasser (m.) und Querschnitt durch Katalysatorschicht (r.) XRM-Aufnahmen: Dummy-Zelle mit Wasser in Kanälen (l.), Querschnitt durch MEA und BPP der Dummy Zelle mit Wasser (m.) und Querschnitt durch Katalysatorschicht (r.)

Further projects

Interface – Microstructured Bipolar Plates for Greater Power Density and Service Life

Using innovative laser-based microstructuring, this research project optimises the interface between the bipolar plate and the gas diffusion layer in fuel cells. This improves water flow and reduces electrical contact resistance, resulting in a performance increase of up to 30% and a significantly longer service life.

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HRS-Model – Free Simulation Model for Calculating Hydrogen Refuelling Systems

Designing hydrogen refuelling systems for reliable and safe operation is a major challenge due to constantly changing requirements and rapid technological development. The HRS-Modell which has now been published, aims to help.

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BeHyPSy – Lightweight, Air-cooled Fuel Cell Drives for Aviation

The ZBT is developing air-cooled lightweight fuel cells with high power density for research into an innovative, hydrogen-based propulsion system for UAVs and aircraft in the 25 kg to 2 t weight class.

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Test-Brennstoffzelle

Corromap – Real-time Corrosion Measurements for Optimising Fuel Cells

Corrosion limits the performance and service life of fuel cells, which are important for a hydrogen economy. Against this background, the Corromap research project focuses on corrosion measurements during cell operation. Project partners are the South Westphalia University of Applied Sciences in Iserlohn and the Hydrogen and Fuel Cell Center Duisburg (ZBT).

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DAC-2-E-Methane – Storing Surplus Green Electricity in E-methane

Storing green electricity chemically instead of regulating it – this is possible with hydrogen and its derivatives. E-methane is a climate-neutral energy source if the carbon is captured from the air. A project that has now been launched is exploring the technical possibilities.

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M-KaV – Development of a Multi-port Cathode Valve for Fuel Cell Systems

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MUSCL – Degradation Model for Optimising the Operating Strategy of Fuel Cell Trucks

Fuel cell systems can be a sustainable alternative to diesel drives in long-distance lorry transport. In a new research project, ZBT is developing a degradation model to simultaneously maximise the energy efficiency and service life of fuel cells through efficient operating strategies.

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GRETE – Graphite PPS as an Alternative to PFAS

PFAS could soon be banned. Could graphite polyphenylene sufide be an alternative for heat exchanger plates? The ZBT is developing an extrusion process for this material.

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