Innovative research project "RUBIN-DuSwaP" sets new standards in fuel cell manufacturing

In the constant search for more efficient and sustainable energy solutions, hydrogen technology is becoming increasingly important. Hydrogen has the potential to reduce our dependence on fossil fuels and pave the way for a zero-emissions future. Fuel cell stacks, which convert hydrogen into electrical energy, are an important part of this development and provide an environmentally friendly energy source.

The regional RUBIN Alliance (Regional Entrepreneurial Alliances for Innovation) "DuSwaP" is working on a more efficient production of fuel cell stacks in Saxony. A new stacking concept and hydrogen-free test scenarios are being developed.

Die Herausforderung in der Brennstoffzellenproduktion

Die Fertigung von Brennstoffzellen-Stacks ist technisch anspruchsvoll und teuer. Sie erfordert spezialisierte Materialien und Präzisionsarbeit, was zu hohen Produktionskosten führt. Diese Kosten sind ein Hindernis für eine flächendeckende Nutzung von Fahrzeugen und anderen Anwendungen, die auf der Brennstoffzellentechnologie basieren. Genau an dieser Problematik sieht das Bündnis erheblichen Handlungsbedarf und will an dieser Stelle aktiv werden.

The challenge of fuel cell production

Manufacturing fuel cell stacks is technically challenging and expensive. It requires specialized materials and precision work, resulting in high production costs. These costs are an obstacle to the widespread use of vehicles and other applications based on fuel cell technology. This is where the Alliance sees a significant need for action and intends to take action.

The goal of "RUBIN-DuSwaP"

The RUBIN alliances, funded by the German Federal Ministry of Education and Research (BMBF), aim to improve cooperation between companies, universities and research institutions. The aim is to jointly create innovative solutions with high application potential.

In view of the expected market development for hydrogen applications, "DuSwaP" specifically targets the research and implementation of manufacturing solutions for the efficient production of fuel cell and electrolyzer systems. A dual stacking concept will significantly shorten the production of fuel cell stacks. First, mini-stacks are produced, which are then assembled into complete stacks. This shortens stacking times and reduces failure rates and repair costs.

The research activities are divided into the four competence areas "Dual Stacking", "Low Hydrogen Testing", "Process Monitoring" and "Disassembly", so that not only several stages of the value chain are considered, but also concepts for recycling and repair of stacks are addressed for the first time.

As one of a total of 14 partners, SITEC is involved in the application and technology development of high-rate laser welding of bipolar plates in the context of steadily increasing volume requirements. Together with partners XENON Automatisierungstechnik GmbH and KIESELSTEIN International GmbH, continuous double stacking is also being researched.