Fraunhofer Institute for Production Technology IPT
Fraunhofer Institute for Production Technology IPT
Laserschneiden einer Bipolarplatte
© Fraunhofer IPT

Manufacturing of bipolar plates

We have mastered both the forming processes and the downstream laser processes for the production of bipolar plates. In discrete or continuous production scenarios, we cut bipolar plate shells using a laser and weld two pieces together in the next process step to form a bipolar plate.

© Fraunhofer IPT

© Fraunhofer IPT

High-precision laser processing

Precise cuts and weld seams can be produced with a laser spot diameter of 35 µm for laser cutting and 38 µm for laser welding. We would be pleased to develop the ideal cutting and welding solutions for your application, too. Get in touch with our experts!

© Fraunhofer IPT

Highly Focused with the Laser: From Process Development to Production Systems

The highly focused laser beam enables materials such as sheet metal, plastic, fiber-reinforced composites, and glass to be processed with high precision. Laser cutting and welding processes are highly productive thanks to a combination of high laser power and dynamic beam deflection, achieving repeatable processing results in the micrometer range.

Industry benefits from the capabilities of laser technology: In the aerospace sector, brittle and hard materials as well as high-performance materials are processed with precision. In the automotive industry, the laser beam cuts and welds thin sheet metal quickly and cleanly. In medical technology, too, the technology is used for high-precision cuts in the manufacture of implants and medical devices. In electronics manufacturing, the laser beam is used to separate wafers and perform micro-cutting of the finest metal structures. In general, the laser enables burr-free cuts in metals, heat-sensitive plastics, ceramics, glass, and sheet metal.

We know how to leverage these advantages for our project partners: We develop and optimize production processes and determine the optimal parameters for each specific application—right through to integration into existing production facilities. We cover the entire development chain, from the process and component levels to complete system integration. In doing so, we integrate sensor technology into manufacturing systems and use AI-based methods for process monitoring, particularly in industries with high-tech applications such as hydrogen technologies, battery production, and semiconductor manufacturing.

Our services at a glance

  • Development of machining strategies and process parameters
  • Feasibility and economic viability studies
  • Pre-production tryout: Rapid prototyping of components
  • Technology consulting for laser cutting and welding processes
  • Adaptation of processes to existing manufacturing environments
  • Custom-configured laser systems for stationary and continuous processes
  • Prototype manufacturing of precision components and microstructures
  • Modular system solutions: Design and construction of machine and module prototypes

The laser beam as a universal tool

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The great strength of ultrashort-pulse laser cutting (USP cutting) lies in applications where burr formation, heat affect zones, or material embrittlement push conventional methods to their limits. This technology is the right choice when edge quality and dimensional accuracy—rather than speed—are critical.

Ultrashort-pulse laser cutting (USP cutting) uses laser pulses in the femtosecond to picosecond range. The pulses are so short that the material is ablated instantly before heat can dissipate into the surrounding area. There is no melting, no burr, and no heat-affected zone.

This “cold ablation” makes the process particularly suitable for materials that are sensitive to heat or mechanical pressure—including glass, ceramics, and composites. The energy is introduced into the material via nonlinear absorption. This unique energy input allows even brittle and sensitive materials to be processed without creating microcracks. The process works equally well on conductive and non-conductive materials and requires no chemicals or coolants.

Continuous-wave laser: For thin sheets with cutting tolerances in the micrometer range

A highly focused continuous-wave laser can be used to cut metals such as titanium, stainless steel, aluminum, and nickel into thin sheets. The process is suitable for material thicknesses ranging from 0.02 mm to 2 mm and achieves cutting tolerances in the micrometer range.

We address typical challenges in thin-sheet cutting—such as burr formation, edge oxidation, or geometric distortion—through targeted parameter selection and customized process configuration. We identify the optimal cutting parameters for each application and, if necessary, develop custom test setups and machine prototypes.

Equipped with a continuous-wave laser source and optics for precision cutting, our system can be used for a gas-assisted laser cutting process.

Laser technologies for fuel cells and electrolyzers

The high precision of our laser processes is particularly evident in one application: the manufacture of fuel cells and electrolyzers. As part of the energy transition, these products will see increasing market demand. To meet this demand, industry must establish large scale production facilities to cut and weld bipolar plates efficiently and sustainably. In addition, our laser technology is also suitable for other hydrogen components: We use the laser beam to cut membrane electrode assemblies (MEAs) and porous transport layers (PTLs) with precision and speed.

You can see how this works in the video here:

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Macro welding: Welding components – large and small

In macro laser welding, we join large components with high power and deep penetration. Micro laser welding, on the other hand, focuses on highly precise, highly localized joints, where we precisely control heat input, weld bead geometry, and thermal deformations at the micrometer level.

Micro laser welding presents significant technical challenges that go far beyond simply scaling down conventional welding processes. The extremely small weld volumes and minimal heat-affected zones require precise adjustment of the laser parameters as well as the highest accuracy in clamping and positioning the components.

Material combinations common in micro-applications—such as different metals, thin films, or heat-sensitive assemblies—are extremely sensitive to energy input. That is why we develop carefully tailored process strategies. The interaction between laser radiation and material on the microscale generates complex phenomena such as plasma shielding, spatter formation, or vapor capillary instabilities, which compromise the quality of the joint.

To achieve reproducible, defect-free welds, we first gain a deep understanding of the process, then select material-specific approaches, employ advanced monitoring systems, and calibrate the entire system with the highest precision.

Expertise you can rely on

Our interdisciplinary team combines expertise in laser physics, process development, system integration, and quality assurance. We develop customized solutions for your specific micro-welding applications and support you from initial feasibility studies through parameter optimization to the implementation of fully integrated production systems.

We use state-of-the-art laser sources—including short pulse and fiber lasers—adaptive, high-precision beam guidance, and real-time process monitoring to achieve robust and repeatable micro-welding processes.

Whether medical devices, electronic components, sensors, or precision instruments: Fraunhofer IPT supports you in transferring micro-laser welding technology from the laboratory to industrial applications.