Fabrication process analysis and experimental verification for aluminum bipolar plates in fuel cells by vacuum die-casting

► We fabricated aluminum bipolar plate using vacuum die casting. ► Optimal die design was selected by simulation. ► The higher the injection speed of the high-speed region, the more effective the formability. ► In case of bipolar plate, vacuum die casting is beneficial in terms of formability compared to conventional die casting. ► Vickers hardness of fabricated bipolar is about 75 Hv.