Bipolarplates using FDM-Mold

The aim was to investigate, if the FDM process is suitable for the production of tool inserts (negative molds), which enables the production of finely textured metallic bipolar plates (BPP) to realize the efficient production of fuel cells.

The first part of the project was to define and design the finely structured hydrogen channel, taking the requirements of the subsequent production steps into account. There, the limitations of the FDM-Process in this area of application and the resulting mechanical properties and geometrical characteristics has to be investigated.

Finely textured mold with good surface quality and sufficient mechanical properties for a small series production of metallic bipolarplates. Identification of suitable materials for this application using the FDM-Process and investigations on orientation angles for optimal canal depths and shapes.


  • Performance: up to 62% higher
  • Speed: 5 times faster
  • Space: up to 50% thinner

This Innovation was developed together with Eisenhuth GmbH & Co. KG. Eisenhuth. Eisenhuth is SME located in Germany, Osterode am Harz, and has three main competencies: Mold making, small and medium series of thermoplast, rubber, silicone and thermoset components and the production of bipolarplates from graphite compound materials. In this place the DMRC want to thank Eisenhuth for the great contribution.

Funded by

The Deutsche Bundesstiftung Umwelt DBU (German Federal Environmental Foundation)


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Prof. Dr. Thomas Tröster

Direct Manufacturing Research Center (DMRC) (until 2022)