Cracks in the Stack: Challenges Constraining the Bipolar Plates Market

Despite their importance in fuel cells, bipolar plates face several material, cost, and scalability challenges. Addressing these issues is crucial to enabling broader adoption of hydrogen fuel cell technologies.

According to Stratview Research, the fuel cell bipolar plates market was estimated at USD 0.6 billion in 2024 and is likely to grow at a CAGR of 22.7% during 2024-2035 to reach USD 6.5 billion in 2035.

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Challenges

• Material Limitations: Graphite offers high conductivity but is brittle and costly, while metals require complex coatings to resist corrosion.

• Processing Complexity: Machining or molding plates with precise flow channels adds to lead times and production costs.

• Durability Issues: In mobile applications, plates must withstand vibration, humidity, and thermal cycling—often leading to premature failures.

• Supply Chain Bottlenecks: There is a limited number of specialized manufacturers for advanced bipolar plates, creating bottlenecks in scaling.

Conclusion

To support the global push toward hydrogen-based energy, manufacturers must address these challenges through material innovation, process optimization, and supply chain expansion.