{"id":16723,"date":"2026-07-08T07:37:32","date_gmt":"2026-07-08T07:37:32","guid":{"rendered":"https:\/\/zbt.de\/projects\/scope-efficient-welding-of-compound-bipolar-plates\/"},"modified":"2026-08-24T07:39:59","modified_gmt":"2026-08-24T07:39:59","slug":"scope","status":"publish","type":"project","link":"https:\/\/zbt.de\/en\/projects\/scope\/","title":{"rendered":"SCoPE \u2013 Efficient Welding of Compound Bipolar Plates"},"content":{"rendered":"
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SCoPE \u2013 Efficient Welding of Compound Bipolar Plates for PEM Fuel Cells<\/h1>\n

As part of the IGF SCoPE project, ZBT and SKZ are developing an innovative joining process for bipolar plates made of highly filled polymer compounds. The goal is to reliably weld embossed bipolar half-plates and thereby produce corrosion-resistant, cost-effective, and durable components for low-temperature PEM fuel cells. <\/p>\n<\/h4>\n

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New Joining Methods for Key Fuel Cell Components<\/h2>\n

Bipolar plates are key components in fuel cells. They influence the cost, weight, power density, and long-term stability of the entire system. The SCoPE project focuses on bipolar plates made of composite films, which can offer advantages over metallic solutions in terms of corrosion resistance and cost-effectiveness. <\/p>\n

To this end, the project partners are developing a process that allows extruded and embossed bipolar half-plates made of highly filled polymer compounds<\/a> to be welded together into complete bipolar plates. Among other methods, thermal contact welding, thermal impulse welding, and ultrasonic welding are being investigated as the technological basis for this process. <\/p>\n<\/div>\n<\/section>\n

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From the Compound to the Validated Bipolar Plate<\/h2>\n

The ZBT develops the polymer compounds, extrudes films from them, and embosses them into bipolar half-plates. In addition, the institute handles key aspects of material and component characterisation – particularly for compounds, compound films, and embossed bipolar half-plates. Finally, an in-situ stack test<\/a> is conducted to validate the welded bipolar plates under conditions that closely resemble real-world fuel cell applications. The processes and characterisation methods used in the project build on the ZBT\u2019s research and development achievements<\/a><\/strong>. <\/p>\n

The SKZ develops and optimises welding processes. First, established methods are examined; then, a suitable joining process is specifically refined. The bipolar plates welded in this manner are comprehensively characterised, particularly with regard to mechanical and chemical stability as well as electrical and thermal conductivity at the joints. <\/p>\n<\/div>\n <\/div>\n

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Relevance for the hydrogen economy, small and medium-sized enterprises, and a resilient energy supply<\/h2>\n

SCoPE addresses a challenge in the manufacture of compound-based bipolar plates<\/a> that has not yet been sufficiently investigated. Improved joints can help make fuel cells more durable, more efficient, and more cost-effective. This makes the project particularly relevant for small and medium-sized enterprises that cover key parts of the fuel cell technology value chain. <\/p>\n

The results are also important in terms of new markets: Fuel cell systems are once again gaining prominence, for example in stationary power and energy supply solutions, decentralised fast-charging infrastructure for electric mobility, data centers, and resilient power supply systems. SCoPE is thus contributing to the further development of robust PEM fuel cell components for future hydrogen applications. <\/p>\n<\/div>\n <\/div>\n

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Project information<\/h2>\n

Project:<\/strong> SCoPE \u2013 Welding of Extruded and Embossed Compound Films into Bipolar Plates for PEM Fuel Cells
\nDuration:<\/strong> 1 June 2026, to 31 May 2028
\nGrant ID:<\/strong> 01IF25110N
\nFunding program:<\/strong> Industrial Collaborative Research
\nTotal project expenditures:<\/strong> \u20ac519,992.33
\nZBT share:<\/strong> \u20ac248,632.25
\nProject partners:<\/strong> SKZ \u2013 The Plastics Center, ZBT \u2013 The Hydrogen and Fuel Cell Center<\/p>\n<\/div>\n<\/section>\n

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SMEs Wanted: Join the Project Oversight Committee<\/h2>\n

Are you a small or medium-sized enterprise looking to contribute your expertise to the project and benefit from the results early on? Then join us online via Microsoft Teams for the first meeting of the project steering committee on 29 September 2026, from 9:00 a.m. to 11:30 a.m.<\/strong> We are looking for SMEs that would like to actively contribute their practical experience, requirements, and perspectives to the project. Contact Elisabeth now (contact details below) to reserve your spot.<\/strong> All participants will receive the Teams link well in advance of the event.<\/p>\n<\/div>\n <\/div>\n

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Questions about the project?<\/h3>\n
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\n Elisabeth Verweyen\n <\/div>\n <\/div>\n
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\n <\/svg><\/i>\n +49 203 7598-1172<\/span>\n <\/div>\n
\n <\/svg><\/i>\n \n e.verweyen@zbt.de<\/a>\n <\/span>\n <\/div>\n <\/div>\n <\/div>\n
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Other current projects<\/h2>\n \n
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pAST-EL – Predictive AST Protocols for Alkaline Electrolysis<\/h4>\n

As part of the pAST-EL project, ZBT and DLR are developing predictive stress tests and machine learning models to detect degradation more quickly, predict service life more reliably, and optimise operating strategies for electrolysers.<\/p>\n <\/div>\n

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grELjet<\/h4>\n

As part of the grELjet project, ZBT is collaborating with Fraunhofer ENAS to develop spatially resolved, optimised catalyst layers designed to reduce the iridium requirements of PEM electrolysers and increase their efficiency.<\/p>\n <\/div>\n

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NH3-HRS<\/h4>\n

The NH3-HRS project is developing a compact system that converts ammonia directly into high-purity hydrogen at hydrogen refueling stations.<\/p>\n <\/div>\n

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H2B \u2013 Is Hydrogen the Right Solution for Energy-Intensive SMEs?<\/h4>\n

New Interreg Project H2B Provides Entrepreneurs with Clarity on Hydrogen as an Energy Solution.<\/p>\n <\/div>\n

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GALWANi \u2013 Nanowire Electrodes for Alkaline Water Electrolysis<\/h4>\n

The GALWANi project is developing customized nickel and nickel-iron nanowire electrodes for more powerful and efficient alkaline electrolysers.<\/p>\n <\/div>\n

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TRUST – Safe Hydrogen Trailers for Small and Medium-Sized Businesses<\/h4>\n

The IGF project TRUST (Trailer Refueling Utilizing Simulated Tables) focuses on developing safe refueling procedures for hydrogen trailers.<\/p>\n <\/div>\n

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LongCell \u2013 Fuel Cell Lifespan Prediction and Lifespan-Optimised Operation<\/h4>\n

How can fuel cell systems be operated more efficiently, with a longer service life, and more cost-effectively? The new LongCell research project is dedicated to addressing this question. <\/p>\n <\/div>\n

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