Fabrication of PEM fuel cell bipolar plates by selective laser sintering

The paper presents a new manufacturing technique involving Selective Laser Sintering (SLS) for proton exchange membrane fuel cell (PEMFC) bipolar plate fabrication. A material system for bipolar plate fabrication was identified to satisfy both the cell performance requirements and SLS operation restrictions. Particle size showed significant influence towards the success of SLS bipolar plates. Carbonization and liquid epoxy infiltration were subsequently performed following the completion of SLS green parts. The finished SLS bipolar plate showed impressive surface finish and mechanical strength, and a single fuel cell was assembled with two SLS end plates and membrane electrode assembly (MEA) in between. Various physical property tests were performed with positive results.