Dana Incorporated is blazing a new trail for hydrogen and fuel-cell technology: October 2023, marked the launch of Europe’s largest metallic bipolar plate production at Dana’s operations in Neu-Ulm, Germany. The bipolar plate is a major component in fuel cells and crucial for the successful future of emissions-free hydrogen-powered mobility. A traditional groundbreaking ceremony for the new production line was held on the premises of REINZ-Dichtungs-GmbH in August 2022. Production for metallic bipolar plates is now up and running just one year later.
Ready for Production
An existing logistics building with 4,000 m² of floor space has been converted for bipolar plate production. All production processes are conducted under clean room conditions with the strictest cleanliness requirements.
The plates are cut and formed in two large presses and then cleaned, welded, and coated. With the first metallic bipolar plates rolling off the line this year, the full capacity of eight million annually will be reached in 2024.
The plates are used to make fuel-cell stacks, which generate electricity. These stacks are mainly used in fuel-cell drives for hydrogen-powered vehicles, with up to 900 metallic bipolar plates needed for each vehicle.
Metallic Bipolar Plates
Fuel cells convert hydrogen and oxygen into electrical energy in a cold combustion process. In addition to electricity, the reaction’s only other byproducts are water and heat. The bipolar plate maintains the optimal distribution and balance of hydrogen, oxygen, and coolant.
The fuel cell is made up of fuel cell stacks which consist of bipolar plates and a membrane electrode assembly. The electrical energy to propel the hydrogen vehicles is generated in the fuel cell stacks. The challenge is to develop and produce a compact, durable, and cost-effective bipolar plate in order to make the fuel cell viable for the mass market.
By placing the metallic bipolar plate into mass production, Dana is helping to develop the growing global hydrogen-powered mobility industry.
Ready for the Future
In addition to the new high-volume line, Dana’s Neu-Ulm operation is running a smaller production line with a capacity of 800,000 plates per year. Dana will continue to use this line to produce bipolar plates according to individual customer specifications.
By expanding metallic bipolar plate production, Dana is making steady progress in its transformation to sustainable mobility solutions. The company is making use of unique technological features and competitive advantages from internal-combustion engines to develop innovations for the electrification of mobility – from battery to fuel-cell technology.
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