{"id":10599,"date":"2025-02-10T16:14:06","date_gmt":"2025-02-10T16:14:06","guid":{"rendered":"https:\/\/prod.zbt.compositas.io\/?page_id=10599"},"modified":"2025-08-01T14:44:58","modified_gmt":"2025-08-01T14:44:58","slug":"manufacturing-process","status":"publish","type":"page","link":"https:\/\/zbt.de\/en\/services\/manufacturing-process\/","title":{"rendered":"Production Processes"},"content":{"rendered":"
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Production Processes<\/h1>\n

Precision, Efficiency and Quality at every Stage of the Process<\/h4>\n

The development and production of high-performance fuel cells requires a deep understanding of complex manufacturing processes. From coating technology to component manufacturing and assembly to quality assurance, our portfolio covers all key process steps<\/strong>. Our interdisciplinary approach enables us to develop technologies holistically, scale them and transfer them to series production \u2013 with the highest standards of technical excellence and cost-effectiveness.<\/p>\n<\/div>\n <\/div>\n<\/section>\n\n\n

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Layer Technology<\/h2>\n

Layer technology comprises innovative coating processes<\/strong> for the manufacture of high-performance fuel cell components. Specialised technologies enable the precise application<\/strong> of functional layers, optimising efficiency, durability and performance. A particular focus is on scaling<\/strong> these processes for industrial applications. <\/p>\n<\/div>\n<\/section>\n\n\n

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Coating Processes<\/h2>\n

Coating processes play a crucial role in the manufacture of membrane electrode assemblies<\/strong> (MEAs) and metallic bipolar plates. High-precision application technologies ensure homogeneous material distribution and optimise the electrochemical performance of the fuel cell. <\/p>\n

<\/br>An important approach is the production of catalyst-coated membranes<\/strong> (CCM) using iCCM<\/strong> (indirect CCM) and dCCM<\/strong> (direct CCM). While in the iCCM process the catalyst is first applied to a carrier material and then transferred to the membrane, in the dCCM process it is applied directly to the membrane. Both methods require high-precision coating processes to ensure uniform catalyst distribution and minimise material loss. <\/p>\n

<\/br>In addition to CCM production, the coating of metallic bipolar plates<\/strong> also plays a central role. These coatings improve electrical conductivity, increase corrosion resistance and reduce contact resistance between components. The choice of coating process depends on the specific requirements of the application, with PVD (physical vapour deposition), ALD (atomic layer deposition) and electroplating being widely used. <\/p>\n

<\/br>Continuous optimisation<\/strong> of these processes is essential to further increase the performance and service life of fuel cell systems and to make their industrial production efficient.<\/p>\n<\/div>\n <\/div>\n

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Component Production<\/h2>\n

The manufacture of components for fuel cells requires high-precision manufacturing processes<\/strong> to ensure optimum functionality and durability. Modern processes play a decisive role, from material development and dispersion production to the integration of functional layers. In particular, the adaptation of materials to specific coating and production processes is essential to ensure consistently high quality. <\/p>\n

The use of innovative production technologies such as forming processes and continuous processes<\/strong> for the manufacture of graphitic bipolar plates<\/strong> or dispensing techniques for seal application<\/strong> can make manufacturing processes more efficient and economical. The close integration of materials research and production technology enables the development of high-performance components that meet the increasing demands on fuel cell systems. <\/p>\n<\/div>\n<\/section>\n\n\n

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Dispersion Production and Integration of Functional Layers<\/h2>\n

The development and manufacture of tailor-made catalyst and functional layers for fuel cells requires precisely formulated dispersion production<\/strong>. Active materials, binders and solvents are mixed in a targeted manner to produce a homogeneous suspension with optimum properties for the coating process. The choice of components has a significant influence on the electrochemical activity, mechanical stability and durability of the layers. <\/p>\n

<\/br>A key aspect is the adaptation of the dispersion to the coating process<\/strong>. Different application techniques such as slot die, spray or squeegee coating require specific viscosities and particle size distributions to ensure uniform layer formation and optimum adhesion. <\/p>\n

<\/br>In addition, the integration of functional layers<\/strong> plays an important role. Reinforcement layers increase mechanical stability, while recombination layers contribute specifically to reducing gas transmission. The combination of different material layers enables targeted performance enhancement and adaptation to different operating conditions. <\/p>\n

<\/br>The close integration of material development, process technology and quality assurance enables the realisation of optimised coating systems<\/strong> that are suitable for industrial applications as well as for scaling up to mass production.<\/p>\n<\/div>\n <\/div>\n

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Continuous Processes, Injection Moulding and Dispensing Technology<\/h2>\n

The manufacture of complex fuel cell components requires precise manufacturing technologies that guarantee high quality, dimensional accuracy and repeatability. <\/p>\n