Developing lightweight porous distributors for polymer electrolyte fuel cells via laser powder bed fusion

Polymer electrolyte fuel cells (PEFCs) are key in sustainable energy solutions, particularly in transportation, maritime, and aviation. However, the weight and volume of conventional bipolar plates remain significant barriers to high power densities and widespread adoption. Through simulation and experiments, the nickel foam bipolar plates improve oxygen concentration by 35 % across active area and increase the limiting current by 50 %. Despite these benefits, the high density of nickel limits improvements in gravimetric power density. This study presents the first demonstration of lightweight porous titanium bipolar plates for PEFCs, fabricated via Laser Powder Bed Fusion (LPBF) using an engineered Kelvin cell lattice. A parametric study evaluates the effects of key structural parameters, including cell size, ligament, and sample thickness on PEFC performance. The optimised titanium lattice, with 1 mm cell size, 125 μm ligament, and 1 mm thickness, demonstrated significant improvements. Experimental results showed a 30 % increase in power density and a 60 % enhancement in limiting current compared to a conventional serpentine flow-field. Furthermore, it achieved 25 % higher power than nickel foam bipolar plates while offering a significantly lighter design. These findings highlight the potential of LPBF-fabricated titanium lattices as high-performance, lightweight alternatives for next-generation PEFCs and electrolysers. • Nickel foam BPPs increase oxygen by 35 % and boost limiting current by 50 % over serpentine. • LPBF-fabricated titanium porous BPPs enhance PEFC performance with lightweight design. • Smaller ligaments (125 μm) improve power density and water removal. • Ti LPBF BPP outperforms serpentine flow-field by 30 % in power and 60 % in limiting current. • Ti LPBF BPP delivers 25 % more power and 150 % higher gravimetric power density than Ni foam.