AIM-PLATES is a European collaborative project focused on developing the next generation of sustainable composite bipolar plates for Proton-exchange membrane (PEM) fuel cells. By combining advanced materials, innovative manufacturing processes, and digital technologies, the project aims to strengthen Europe’s competitiveness and accelerate the transition toward clean hydrogen technologies.

The transition to climate neutrality in Europe requires the rapid and cost-competitive deployment of PEM fuel cells; however, bipolar plates (BPPs), which account for approximately 80% of the stack’s weight and 40% of its cost, remain a bottleneck. Current supply relies on imported metal or graphite plates, exposing EU value chains to risk.

The manufacturing of composite bipolar plates (cBPPs) is not yet fully mature (long production cycles, high scrap rates, fragmented digital control). OEMs demand proven durability, certification-ready quality, and scalable, circular processes for both low- and high-temperature PEM fuel cells.

AIM-PLATES combines advanced forming and shaping techniques with a ZERO-X digital infrastructure (digital twins, in-line quality assurance, adaptive control) within an SSbD framework. This approach is demonstrated across two complementary EU pilot lines at TRL7: Pilot 1 (thermoplastic/carbon) produces ultra-thin, high-performance, and remanufacturable plates; Pilot 2 (bio-based thermoset/(graphite + biocarbon)) produces cost-effective, robust, and renewable plates.

Both lines aim for “right-first-time” manufacturing with a low carbon footprint. Demonstrators in aviation (short-stack HT-PEMFC) and road transport—specifically light commercial vehicles (LT-PEMFC as primary; HT-PEMFC for early adoption/short stacks) will prove the feasibility of manufacturing and integration, generate comparative datasets against existing solutions, and de-risk adoption.

The project is structured around seven work packages covering materials, processes, pilot line development, digital infrastructure, demonstrations, sustainability, standardization roadmap development, skills, and market exploitation and adoption. It aims to generate new knowledge and validated industrial assets, as well as an exploitation strategy aligned with the NZIA, Clean Hydrogen JU SRIA, and Made in Europe initiatives. By 2030, AIM-PLATES will strengthen EU sovereignty in hydrogen technologies by reducing reliance on imported BPPs and fossil-based inputs, cutting CO₂ emissions per plate by up to 60%, and establishing pathways for application to electrolyzers, flow batteries, and other net-zero technologies, Industry 5.0-related skills within the EU.