The paper presents a new manufacturing technique involving Selective Laser
Sintering (SLS) for proton exchange membrane fuel cell (PEMFC) bipolar plate
fabrication. A material system for bipolar plate fabrication was identified to satisfy both
the cell performance requirement and SLS operation restriction. Carbonization and liquid
epoxy infiltration are subsequently performed following the completion of SLS green
bipolar plate. The finished SLS bipolar plate showed impressive surface finish and
mechanical strength, and a single fuel cell was assembled with two SLS end plates and
membrane electrode assembly (MEA) in between. Various physical property tests were
performed with positive results. Fuel cell performance (voltage vs. current density,
voltage vs. time, etc.) will be assessed in the near future.Mechanical Engineerin
