This article presents the results of exploratory research on novel methods for the
fabrication of functional, metallic, gas flow, bi polar plates (BPP) for use in proton
exchange membrane fuel cells (PEMFC). Low cost, high speed, additive manufacturing
methods that combine 3D printing (3DP) and thermal spray (TS) technologies are
described. Functional flow plates were manufactured by creating 3DP patterns and then
depositing, and releasing, dense metals with TS methods. The new method yields dense
metal plates, with interesting options for material choices and complex designs.Mechanical Engineerin