The automotive supplier Dana is expanding its hydrogen portfolio with a metallic bipolar plate for electrolysers. The component was developed at the Neu-Ulm site and combines forming technology, a conductive coating, and an integrated elastomer seal.
The plate is made of titanium or steel and is manufactured using a high-speed forming process. According to the company, this allows for the realisation of complex flow field geometries with consistent series quality. A conductive coating ensures electrical performance, while an overmoulded elastomer seal guarantees tightness over a wide temperature range. With a material thickness of around 0.1 millimetres and formats up to 800 × 800 millimetres, more plates fit into the same stack volume. This is intended to increase power density and reduce costs per kilowatt.
“Our bipolar plate combines material expertise with mass production. This makes green hydrogen more competitive,” says Philipp Konrad, Head of eMobility Products at Dana in Neu-Ulm. According to its own statements, Dana brings experience in stamping, embossing, coating, and elastomer processing. The company, headquartered in Maumee, Ohio, USA, achieved a turnover of 7.5 billion US dollars in 2025 and employs 28,000 people in 24 countries.
