Transparent cost analysis of hollow embossing rolling vs. hollow embossing for industrial BPHP production

Abstract Metallic bipolar half plates (BPHPs) represent a major cost driver in fuel cell and electrolyzer systems, making cost-efficient high-rate manufacturing essential for industrial deployment. This study presents a transparent and industrially grounded cost modelling framework for the systematic comparison of two forming technologies: conventional hollow embossing (HE) and continuous hollow embossing rolling (HER). Based on a uniform reference production scenario, the model integrates investment, tooling, machine, and material costs, explicitly considering production rates, tool life, overall equipment effectiveness, and process-specific boundary conditions based on cost data derived from industrial practice and equipment procurement experience. In addition to a detailed cost structure analysis, comprehensive sensitivity and scenario analyses are performed to assess the robustness of the results against uncertainties in key parameters. The results show that HER provides substantial economic advantages, reducing manufacturing costs per BPHP by up to 39 % and total costs by approximately 28 % in the reference case. Across all investigated scenarios, HER demonstrates a robust cost advantage, with expected total cost reductions in the range of 23 % to 37 % compared to HE. The study contributes a transferable methodology for the economic evaluation of alternative forming processes under industrial conditions and provides a quantitative basis for decision-making in large-scale production system design for fuel cell components.