Injection compression molding of bipolar plates

Injection compression molding is an innovative plastics processing method in which a polymeric material is injected into the tool under extremely high pressure to produce components with precise geometric properties. The process begins with heating the plastic granulate before it is injected into the molding chamber via an injection nozzle, where it cools and solidifies under controlled conditions. By using this process, not only complex and finely structured geometries can be realized, but also very precise details on a microscopic level, which makes the method particularly suitable for applications with high demands on dimensional accuracy. A key advantage of the injection compression molding process is its high repeat accuracy, which makes it possible to produce almost identical components on a large scale, making it particularly suitable for series production. In this context, dynamic process control plays a central role, as it requires the continuous adjustment of parameters such as temperature, injection speed and pressure in order to optimize the quality of the manufactured products and minimize any material losses. By precisely controlling these variables, not only can the desired mechanical and thermal properties of the end products be guaranteed, but the efficiency of the entire production process can also be increased.

High-precision bipolar plates for hydrogen technology – innovation through dynamic injection compression molding

Fuel cell technology plays a key role in the energy transition and the increasing electrification of mobility and energy supply. Hydrogen offers a promising alternative to fossil fuels, particularly in heavy-duty transportation, aviation and stationary energy storage systems. Bipolar plates, which are the core components of fuel cells and are responsible for the distribution of reaction gases and the transportation of electricity, are a crucial part of this technology.

The research project is dedicated to the development of high-precision bipolar plates made of polymer compounds using an innovative injection compression molding process with dynamic mold temperature control. The aim is to increase the efficiency and cost-effectiveness of fuel cell production by reducing material costs and improving manufacturing accuracy. Compared to conventional metal solutions, plastic-based bipolar plates offer advantages such as high corrosion resistance, lower weight and lower production costs. At the same time, the processing of highly filled plastic melts and the precise molding of the finest channel structures represent a major technological challenge.

Through the targeted use of temperature and pressure control in the injection compression molding process, the project is investigating new ways of producing thin-walled, highly conductive and durable bipolar plates. The knowledge gained should contribute to the further development of hydrogen technology and enable a broader industrial application of fuel cells. In close cooperation with partners from science and industry, an important contribution is being made to the sustainable energy supply and mobility of the future.