(Invited) Automated Production of High Performance PEMFC Stacks and Components According to Automotive Requirements
Authors: Kraft Juergen , Paul Michael T.Y. , Goetz Michael 
Published: November 2022

EKPO Fuel Cell GmbH was founded in 2021 by two parent companies, ElringKlinger and Plastic Omnium, whom both are strong and established automotive suppliers with mass manufacturing capabilities and strategic approaches to hydrogen and the fuel cell businesses. The aim of EKPO is the development and production of proton exchange membrane fuel cell stack components and stack modules. Drawing from the experiences of the pilot automated production line since 2016, a fully optimized automated production, with improved production technologies and products, was developed by EKPO in 2021 to achieve an output capability of 10,000 stacks per year. The line was designed with a modular and scalable approach that allows flexibility as well as increased capacity by parallelization. The implementation is successful of producing EKPO’s various stack platforms while maintaining a high level of quality and production standard for the automotive industry.

Since EKPO offers a wide range of products, the automated line can cover stack power ranges from 10 kW up to > 200 kW. As a prerequisite for excellent technical performance, in addition to function quality measures were set as key targets from the start of the development. EKPO has thus established consistent and stringent quality process flows and processes for all production steps. These measures include the early involvement of measurability and manufacturability assessment on all process and analysis steps on the different levels (i.e., components and stack). The feedback from each workflow can then continuously improve products, processes, and documentation regarding product specific codes standards and regulations (CSR).

The accumulative knowledge from two decades of activity of fuel cell component and stack development enabled EKPO to establish a production range starting from cell and stack components (i.e., bipolar plates, sealings, and plastic end plate modules) to fuel cell stacks and modules produced by fully automated MEA and stack assembly and end-of-line testing. The automated production covers all processes from bipolar plate manufacturing and assembly, CCM and GDL roll good cutting, MEA-assembly, stacking, and the final compression and characterization of the fuel cell stack. The quality matrixes include inspecting performance key figures as well as quality and geometries of the stack and its components. The incoming materials are typically supplied as roll goods, (i.e., GDL, CCM, and metal coil) or as raw material (i.e., plastic granules). As the incoming materials and finished components are very sensitive to environmental conditions and particle contamination, the entire MEA processing and stack assembly process takes place in a cleanroom with controlled climate for maximum process stability and reliability.

With a key approach of “design to manufacture” and deep understanding of stack technology and component requirements, EKPO is able to deliver two best in class stacks, namely the NM5 evo and NM12 single and twin platforms.