Up to 120 half-plates per minute – hollow-emboss rolling is an efficient, resource-saving forming process that offers clear advantages over conventional methods, especially when producing complex component geometries. The BPPflexROLL and flexROLLmax set new benchmarks for scalable bipolar-plate production.
The BPPflexROLL in operation
Roll pair with punch and die roll: the metal strip runs through continuously.
Reaching cost-efficiency through continuous processes
With the newly developed technology, the structure of the bipolar plate is embossed by a pair of rolls, between which the clamped, wafer-thin metal strip runs continuously. One forming roll acts as the punch, the other as the die. This continuous rolling process enables high-rate production.
Because the rolls forming the flow channels have almost only line contact with the workpiece, the incremental forming reduces process forces by an average factor of 10 compared with conventional hollow embossing. This allows for smaller, more economical equipment. A further advantage lies in the flexibility of the system: the number of roll sets required can be adapted individually to the bipolar-plate geometry.
BPPflexROLL — the roll stand guides the metal strip through several forming stages.
Forming technology for high-rate production
Production rates of >100 BPHP/min
The BPPflexROLL is designed as a flexible, modular forming system for high-rate production and achieves production rates of up to >100 BPHP/min. It can be adapted to different bipolar-plate geometries and production requirements. Its central element is a robust roll stand that ensures continuous transport of the metal strip through several forming stages.
The concept allows roll sets to be freely combined and extended, making the BPPflexROLL suitable both for development work and for near-series applications. Thanks to its compact, scalable design, the system integrates easily into existing production environments and can be expanded step by step.
The flexROLLmax provides a scaled-up version designed in particular for larger component geometries and greater material thicknesses (e.g. electrolyzer plates).
BPPflexROLL
For compact, fine components
High production rates
up to 120 BPHP/min
Max. strip speed
46 m/min (D245)
Max. production width
250 mm
Max. torque
1,800 Nm
Sheet thickness
0.05–0.1 mm
Max. rolling force
75 kN
Roll diameter
240–310 mm
flexROLLmax
For larger components and material thicknesses
High production rates
> 60 BPHP/min
Max. strip speed
25 m/min (D400 mm)
Max. production width
500 mm
Max. torque
4,900 Nm
Sheet thickness
0.1–0.5 mm
Max. rolling force
600 kN
Roll diameter
320–400 mm
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