Patent ID: 8597858

Claim:
A method for producing a bipolar plate assembly for a fuel cell stack, the method comprising the steps of: providing a first substrate and a second substrate, each of the first substrate and the second substrate having an external surface corresponding to a desired flow field pattern, at least one of the first substrate and the second substrate including at least one via formed therein; immersing the first substrate and the second substrate in a plating bath; plating a first predetermined thickness of a plating material on the external surfaces of the first substrate and the second substrate; abutting the first substrate with the second substrate; plating a second predetermined thickness of a plating material on the external surfaces of the first substrate and the second substrate over at least a portion of the first predetermined thickness, the at least one via filled by the plating material when the second predetermined thickness is achieved to bond the first substrate and the second substrate, an external perimeter between the first substrate and the second substrate joined by the second predetermined thickness of plating material to provide a hermetic seal therebetween; and withdrawing the first substrate and the second substrate from the plating bath.