Cell Impact: The Face of Next-Gen Bipolar Plate Forming Technology

The hydrogen energy industry is rapidly advancing with fuel cells and electrolyzers taking center stage in the clean energy transition. At the core of these systems are flow plates—ultra-thin metal sheets that guide gases and liquids while conducting electricity. Manufacturing these plates has always been a complex task. Balancing gas distribution, conductivity, durability, scalability and cost can affect quality, speed and volume of production.

Cell Impact, a premier manufacturer of bipolar plates for hydrogen fuel cells and electrolyzers, overcomes these challenges with its proprietary, high-velocity, dry forming technology. It’s a vast improvement from the multi-step processes used in stamping or hydroforming. The innovative technology produces high-quality flow plates in a single step within shorter timeframes and at a fraction of the traditional production cost.

The patented Cell Impact Forming technology can produce complex geometric shapes with remarkable precision while keeping production scalable and energy-efficient. It creates future-ready designs that meet high-quality standards and include features competitors cannot replicate. It is the only working cost-efficient solution on the market today that is aligned with the future high volume targets of cost and quality for 2030. Cell Impact’s facility in Karlskoga, Sweden houses a large inventory of ready-to-market products.

“Our bipolar plate forming technology pushes the limits of what is formable to enable performance levels clients cannot achieve using other methods,” says Daniel Vallin, CEO.

Backed by years of engineering expertise and extensive testing, Cell Impact serves as a flow plate supplier and a provider of plate manufacturing processes for its clients. Its high-volume production capabilities, state-of-the-art leak testing and advanced measurement instruments for evaluating plate and forming tool dimensions make it the partner of choice for clients.
High-Speed Forming with Performance, Precision and Flexibility

Cell Impact’s technology combines the reliability of conventional methods with proprietary innovations that boost speed and material flexibility.

Its speed-based approach stands in stark contrast to the force-based stamping and hydroforming methods. Despite the widespread use of these techniques, persistent limitations remain. Conventional stamping ensures stability within flow plates, but it comes with limited flexibility and lower production speed. Hydroforming is capable of creating complex geometries and enhancing plate strength. But it often struggles to meet commercial production needs, making it more suitable for prototypes or low-volume runs.

The Cell Impact Forming technology ensures high-performance flow plates that consistently meet volume requirements with shorter lead times.

A single-step forming process is made possible with high kinetic energy. The guiding principle behind this distinct approach is to accelerate the impact cylinder and retract it directly after impact, preventing a double hit.

The energy released from the high-speed impact on the metal sheets induces special material reactions that shape the flow channels. The result is highly complex geometries with larger landings and flatter contact area surfaces in the plates. The intricate geometries promote improved electrical contact between the plate, the gas diffusion layer (GDL) and the membrane electrode assembly (MEA). The designs also ensure more even pressure distribution across the plate.

High-speed forming also ensures even thickness by reducing material deformation issues such as wall thinning and necking and eliminating micro-cracks, which are common manufacturing defects in slower processes. As a result, the plates become stronger and more uniform, contributing to high performance.

Each flow field channel, pitch and angle of the plates can be tailored to client specifications to optimize gas diffusion and electrical conductivity.

Co-Designing Resilient Flow Plates That Build Trust

Cell Impact works closely with clients from the earliest stages of design. Engineers and R&D teams frequently collaborate to transition more quickly from concept to production.

During the design and preparation phase, computer simulations, small test tools and full-scale process validations help predefine flow plate quality requirements.

A stringent quality focus permeates every stage. The quality assurance system includes optical and tactile measuring machines as well as 3D scanning capabilities. They enable the verification of extremely small tolerances; essential for high-precision components.

All plates undergo 100 percent leak testing and visual inspection to detect and remove scratches, dents or other defects. While plate samples are measured periodically during production, the forming tools undergo far more rigorous inspection.

To ensure exceptional product quality, Cell Impact uses a state-of-the-art Hexagon measuring machine, one of the most accurate in the world. The measuring system can verify tolerances as tight as plus or minus five microns, ensuring that each forming tool and finished plate meets exacting dimensional standards for high-performance hydrogen applications.

Control plans, created in collaboration with clients in the development phase, specify which measurements to take, how often and what tolerance limits are acceptable in flow plates. The hands-on approach ensures that plates meet strict requirements while shortening validation cycles and time-to-market.

Post-processing steps, such as coating, sealing and galvo-welding, are carefully controlled to maximize durability and long-term performance. Cell Impact has refined the entire process, which includes forming, cutting, welding and leak testing, over the production of more than 2.5 million flow plates across 80 projects—a feat that inspires client confidence.

In one project, it used high-speed forming to optimize a client’s fuel cell plate geometry. The plates were refined through its simulation and testing capabilities. The result was enlargement of the contact area between the plate and the MEA that increased power output by more than 20 percent compared to the design made with conventional forming techniques.

Cell Impact also shares knowledge and process expertise with clients. The team helps optimize design and improve manufacturability. Equipped with facts, data and explanations, it guides optimization of plate geometry, landing adjustments and channel depth to improve stack performance.

Embedding Sustainability in Every Stage of Production

Sustainability is a core principle of every approach taken by Cell Impact. Long tool life, minimal energy use and dry production processes contribute to a lower carbon footprint.

The machines used for the forming process are smaller and easier to operate and maintain than traditional equipment. They use 85 percent less energy and require no water or lubricants, lowering both environmental impact and operating costs. Forming tools further promote sustainability, with tests showing life cycles beyond three million hits.

Combined, these approaches produce plates with high sustainability. Clients also benefit from a 50 percent reduction in capital expenses and a 40 percent reduction in operational costs.

Ongoing research and development efforts are aimed at enhancing machine capabilities and secondary processes. A key priority is scaling up forming machines to handle the larger plates required for next-generation electrolyzers, which will reduce production costs even more and accelerate the adoption of hydrogen globally. In parallel, smaller machines for applications that demand less force and material are under development.

Cell Impact is also enhancing its capabilities in cutting, welding and leak testing. Investments in new process steps, such as post-coating and sealing solutions, are underway to improve plate quality and expand its applications.

Combining environmental efficiency with cost and performance ensures its technology aligns with the goals of a renewable energy economy. Its environmental focus continues to set new benchmarks for players in the hydrogen economy.

“We are working to find different ways of producing flow plates for fuel cells and the electrolyzers to help support global net-zero initiatives,” says Marcus Nilsson, sales and program manager.

Driving the Hydrogen Economy Forward

Over the past two years, Cell Impact has expanded its customer base by demonstrating the benefits of its technology through validations and measurable results. Confidence in its solutions has kept clients returning with new projects and larger orders.

Advanced forming technology and market-ready high-volume production are placing Cell Impact at the forefront of bipolar flow plate technology. Ready today for tomorrow’s production demands, it is emerging as the support system for fuel cell and electrolyzer providers seeking high-quality, cost-effective and sustainable solutions to make their mark in the growing hydrogen economy.