Sourced

Ready2Stack™ utilises the highest quality customised materials, specified to improve component geometry and ensure high quality throughout the process.

Material

Grade 1 Titanium & Stainless Steel

Thickness

0.1mm to 1.0mm

Active Area

up to 3000cm²

Formed

Precisely formed parts manufactured using innovative forming strategies, enabling maximum design freedom and consistent quality. Automotive quality parts as standard, ranging from small scale prototypes to high volume production of millions of parts. State-of-the-art laser welding is also available for joining half-shells or complete BPPs to auxiliary stack elements.

Min volume

Small scale prototypes

Max volume

8 million BPP pa

Additional processes

State-of-the-art laser welding

Coated

Ready2Stack™ is coated using Resillion™ specialised coating technology to enhance performance efficiency and durability. Resillion™ withstands and protects against oxidation and hydriding, to increase BPP lifespan. It also protects against hydrogen embrittlement, improving fluoride ion tolerance to extend stack lifetime.

Coating type

PGM

Degradation rate

< 4 μV/h

Sealed

Optimised seals for all interfaces and operating conditions, ensuring durability and performance over the stack lifetime. Seals can be injection moulded or dispensed to ensure system specific requirements are met. In-house validation also guarantees consistent component quality and characteristic conformity. Prior to sealing, BPPs can undergo additional processes, such as washing, in preparation for optimal sealing application and the stack environment.

Seal type

Injection moulded or dispensed

Seal materials

FKM, EPDM, silicone rubber

Leakage rate

< 7.2e⁻⁷ mbar∙l/s at 1 bar_g

Corrosion Resistance

Ready2Stack™ provides exceptional fluoride protection during PEMWE operation. The contact resistance remains low even after undergoing corrosion tests.

Polarisation Curves

Ready2Stack™ enables PEM electrolysers to operate at higher current densities, resulting in improved energy efficiency.

Design & Development

Creating each system specific Ready2Stack™ solution involves a meticulous approach to BPP design and manufacture. This process ensures optimum compatibility and in-stack performance.

The resulting BPP is a highly engineered drop-in solution that improves the efficiency of an electrolyser stack, while offering ease of use and simplification of the supply chain.
  • Step 1 - Analysis of requirements and feasibility study

    Full evaluation of customer requirements to define the ideal process flow, enabling the optimal evaluation and selection of both partners and suppliers.

  • Step 2 - Develop and finalise BPP design ready for manufacture

    Our team optimises the component design together with the customer. We see ourselves in an advisory role with regard to the process chain in order to further develop the components not only functionally, but also in terms of process technology. This reduces costs but also increases the robustness and quality of the components. Our team collaborates with customers to optimize component design, advising on the process chain to develop components both functionally and from a process technology perspective. This approach reduces costs while improving robustness and quality.

  • Step 3 - Forming and cutting of plate to automotive quality standards

    Sheet metal forming is a core competence of the HOERBIGER Automotive Division. With decades of experience, we ensure the highest quality in medium to very high-volume parts. Our in-house tool and equipment development guarantees innovation and flexibility to meet the highest customer demands and this expertise has been applied to the manufacture of metallic bipolar plates from titanium and stainless steel.

  • Step 4 - Option of laser welding

    Welding of half-shells is tailored to the customer's concept. HOERBIGER can weld various sheet metal components using advanced laser welding systems, producing prototypes in-house and scaling as required. Our toolmaking expertise ensures high standards for tightness in fixture construction.

  • Step 5 - Application of optimised coating using Resillion™

    The plates are coated using JAMES CROPPPER’s specialised Resillion™ coating technology optimised to enhance conductivity, and protect electrolysers against corrosion and oxidation. Engineered for versatility and scalability, Resillion™ ensures optimal platinum efficiency delivering unmatched performance and extended component life.

  • Step 6 - Additional treatment if required (e.g. technical cleaning)

    Depending on customer requirements, additional steps like part washing or surface activation for subsequent seal application may be needed. We develop specific processes and take care of industrialisation.

  • Step 7 - Application of seals

    The seal is a crucial component of the bipolar plate, essential for both safety and functionality. It must withstand aggressive cell environments, high temperatures, and demonstrate resistance to ageing. Ready2Stack™ offers various technologies tailored to customer requirements. With expertise in injection moulding and dispensing of all common materials (FKM, EPDM, silicone), we are the partner for integrated solutions.

  • Step 8 - Validation and testing

    A final end-of-line test ensures consistent, high-quality features of the bipolar plate, enabling customers to stack components directly. Benefits include minimised waste, reduced logistics costs at the assembly plant, and shorter process times.

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