Chemical Etched Metallic Bipolar Plates With Perfect Flatness for Fuel Cell Stacking

Chemical Etched Metallic Bipolar Plates With Perfect Flatness for Fuel Cell Stacking

Overview

Xinhaisen specializes in high-precision chemical etching of metallic bipolar plates. Using advanced photochemical machining (PCM), we produce burr-free, stress-free bipolar plates for proton exchange membrane fuel cells (PEMFC), solid oxide fuel cells (SOFC), and PEM electrolyzers. Our process ensures ultra-flat channels, tight tolerances, and rapid prototyping to mass production.

Product Features

• Ultra-high precision channels – Minimum line/space width down to 0.015mm; flow field depth uniformity within ±0.05mm

• Micro-hole capability – Coolant/distribution holes as small as 0.03mm diameter

• Thickness range – From 0.5mm to 3.0mm (thin foils for lightweight stacks or thicker plates for rigid designs)

• Material versatility – Stainless steel (304, 316L, 430), titanium (Grade 1/2), nickel-based alloys (Inconel, Hastelloy), copper, and other conductive/corrosion-resistant metals

• Burr-free & stress-free – No mechanical deformation, no micro-cracks, perfect for gasket sealing and membrane contact

• Cost-effective for medium-to-large volumes – Rapid turnaround on prototypes and high-volume orders

Technical Specifications

Typical Bipolar Plate Designs We Produce

• Anode & cathode flow field plates – Parallel, interdigitated, pin-type, or custom patterns

• Cooling plates – Internal cooling channel structures for thermal management

• Single plates & bonded pairs – Etched on one or both sides; alignment features for lamination/welding

• Perimeter sealing grooves – Integrated grooves for O-rings or laser welding

• Manifold/distribution holes – Uniform arrays for reactant/coolant distribution

Why Choose Etching for Bipolar Plates?

• Lower cost than CNC milling (especially for thin metals and fine channels)

• Shorter lead time – No hard tooling wear; design changes via phototool only

• No heat-affected zones – Preserves material conductivity and corrosion resistance

• Scalable – From 10 pieces (R&D) to 500,000+ pieces/month

Quality Assurance

• Inspection – 2.5D/3D measuring microscope, CMM, surface roughness tester

• Standards – ISO 9001:2015 certified processes

• Traceability – Full material certification (mill test reports available)

Industries Served

• Hydrogen fuel cell stacks (automotive, stationary power)

• PEM electrolyzers (green hydrogen production)

• Aerospace & UAV power systems

• Metal-air batteries

• Custom electrochemical cells

FAQ

• Q: Can you etch bipolar plates for fuel cells or electrolyzers?
  A: Yes, we specialize in precision etching of bipolar plates for fuel cells, electrolyzers, and other energy applications using metals like stainless steel and titanium.
• Q: What thickness of metal can you etch for bipolar plates?
  A: We can etch bipolar plates from 0.5mm to 3.0mm thick, with high precision and consistent channel depth.
• Q: How precise are the flow channels on your bipolar plates?
  A: Our etched flow channels achieve uniformity within ±0.05mm, and we can create micro-channels with line widths as fine as 0.015mm.
• Q: Can you produce both anode and cathode sides of a bipolar plate?
  A: Yes, we can etch both sides of a bipolar plate simultaneously or separately, depending on your design requirements.
• Q: What materials do you use for bipolar plate etching?
  A: We work with a range of corrosion-resistant metals including 304, 316L stainless steel, titanium, and nickel-based alloys.
• Q: Do you support low-volume prototyping or only mass production?
  A: We support both — from small R&D batches to large-volume production, with fast turnaround and no tooling costs.

Welcome to contact us at any time!

For over 13 years Xinhaisen has pioneered developments in photochemical etching, achieving standards admired by the industry and appreciated by a global customer base from a wide range of high-tech engineering markets.

Since found in 2012, in affiliating with our customers we have pioneered many new production techniques and methodologies in order to better serve their needs. It is these techniques that have advanced our capabilities further, enabling us to take what was once considered art and turn it into a science.

Now, we became China's leading photochemical etching specialist, with also the capacity of offering stamping and laser-cutting service. Our products include etching bipolar plates for fuel cell, speaker grills,  micro meshes&filters, tea&coffee infusers, shims&gaskets, Optical encoderdisk&strip, EMI/RFI shielding, Leadframes, connectors&contacts, printingstencils&foils and metal crafts.

Quality and service is our mission, Xinhaisen is committed to pursuing the highest standards of environmental performance. Responsibility for sustainability resides with all employees. The company has achieved ISO 14001 and IS0 9001 and IATF 16949 and is committed to maintaining that standard. With a fast response, high quality, best service and fair price, we have gained high reputation from our customers all over the world.