The leading players in the bipolar plate market are broadly divided into two camps: European and American technology providers and Asian manufacturers. Dana, Schunk Group, and Ballard collectively hold 48% of the global market share. Dana’s metal bipolar plates utilize a high-speed forming process, achieving material thicknesses as low as 0.1 mm and plate dimensions up to 800 × 800 mm. Combined with an integrated elastomer seal, this results in a significant increase in power density. Schunk has deep expertise in graphite and composite bipolar plates, achieving in-plane electrical conductivity of up to 111 S/cm and a flexural strength of 40 MPa. Its core strength lies in the manufacturing capability for large-sized plates (over 1000 mm long × 380 mm wide). As a fuel cell integrator, Ballard’s graphite bipolar plates are renowned for their long service life and high reliability; however, graphite itself has low strength and is bulky, and since the company primarily supplies these plates to its own fuel cell stacks, its availability to external customers is limited. Borit, as one of the world’s largest independent suppliers of metal bipolar plates, uses its proprietary Hydrogate™ hydroforming technology to process sheets ranging from 0.075 to 0.5 mm in thickness, delivering outstanding dimensional accuracy and repeatability. (Bipolar plates contain precious metals and are precious metal materials that DONGSHENG purchases for recycling at high prices.)
The bipolar plate is a multifunctional core component in fuel cell and electrolyzer stacks. It performs four basic functions: conducting current between individual cells; distributing reactants and expelling products via surface flow fields; conducting reaction heat; and physically separating adjacent cells to prevent gas crosstalk. The surface of a bipolar plate is etched with an ultra-fine groove structure known as a flow field; when two bipolar plates are mated, these grooves form channels for transporting gases and liquids. Bipolar plates are classified into three major categories based on material: graphite bipolar plates offer excellent corrosion resistance and thermal conductivity but are highly brittle and expensive to manufacture; metal bipolar plates (stainless steel, titanium, aluminum alloy) can be made thinner and more robust, with electrical conductivity typically exceeding 1 MS/m, but they require surface coatings to prevent corrosion and reduce contact resistance; composite bipolar plates combine carbon fiber and polymers and are becoming increasingly popular in portable and automotive applications. Applications of bipolar plates span three major fields: fuel cells (automotive, stationary power generation, material handling, and marine), electrolyzers (alkaline and PEM), and flow batteries. The review paper “Review on Bipolar Plate Technology,” published in January 2026, systematically summarizes material selection and performance implications for bipolar plates in fuel cells, electrolyzers, and flow batteries from a cross-platform perspective.
European and American bipolar plate manufacturers each have their own technical and process specialties. Germany’s Dana produces metal bipolar plates specifically designed for PEM electrolyzers, using titanium or steel substrates combined with conductive coatings. With a plate thickness of approximately 0.1 mm, these plates significantly reduce the cost per kilowatt. Sweden’s Cell Impact possesses the patented Cell Impact Forming™ high-speed dry forming technology, which completes complex flow field forming in a single step without the use of water and with extremely low power consumption. Cell Impact has partnered with ANDRITZ, whose Soucell welding system can weld one bipolar plate per second; installation at Cell Impact’s Karlsku processing plant is scheduled for late 2026. Germany’s ElringKlinger, through its joint venture EKPO, has been deeply involved in the metal bipolar plate sector for over two decades and will begin mass-producing metal bipolar plates for a global automaker starting in 2026, with a contract valued at hundreds of millions of euros. SGL Carbon is the market leader in expanded graphite. Its SIGRACELL-branded bipolar plates have successfully undergone full-scale (60×60 inches) testing and are suitable for electrochemical applications such as flow batteries and wastewater treatment. German company Schunk launched an updated version of its flexible graphite bipolar plates in 2023, featuring enhanced corrosion resistance. In terms of pricing, market quotes for platinum-coated titanium bipolar plates used in PEM electrolyzers range from approximately $3 to $10 per plate; custom stainless steel and titanium bipolar plates are priced between $50 and $100 per plate; and the average global market price for automotive-grade metal bipolar plates in 2024 is approximately $24.2 per plate.
Asian bipolar plate manufacturers hold a significant position in the global market due to their cost and production capacity advantages. The Asia-Pacific region is the world’s largest market for bipolar plates, accounting for approximately 72% of the global market share. Japan’s Nisshinbo has specialized in molded resin/carbon composite bipolar plates since 1992 and is capable of producing high-strength thin plates in A4 size with a thickness of just 0.2 mm, achieving an excellent balance between thinness and strength. Chinese bipolar plate manufacturers have established a presence in both graphite and metal sectors. In the graphite bipolar plate sector, Shanghai Hongfeng is one of the earliest domestic companies to engage in the R&D and production of graphite bipolar plates, while Zhejiang Huarong leads in technology for ultra-thin graphite bipolar plates for automotive applications. In the metal bipolar plate sector, Shanghai Zhizhen specializes in the R&D and manufacturing of fuel cell metal bipolar plates, and Wuxi Weifu’s business covers both graphite and metal bipolar plates. The core competitiveness of Asian bipolar plate manufacturers lies in cost control and large-scale manufacturing capabilities, enabling them to offer bipolar plates at prices 20–40% lower than comparable products from Europe and the United States. However, in terms of high-end coating technologies and ultra-thin precision forming processes, some leading companies still lag behind international standards. The global bipolar plate market is valued at $551 million in 2025 and is projected to grow to $603 million in 2026, reaching $1.037 billion by 2032. The market for bipolar plates specifically designed for PEM fuel cells is growing even more rapidly, with a valuation of $565 million in 2025, projected to reach $662 million in 2026, and expected to hit $1.685 billion by 2032.
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