AIM-PLATES · AI-Enhanced Sustainable Manufacturing of Composite Bipolar Plates for Cross-sectoral Net-Zero Technologies

Europe’s climate-neutral transition needs rapid, cost-competitive PEM fuel-cell deployment, yet bipolar plates (BPPs), ~80% of stack weight and 40% of its cost, remain a bottleneck. Current supply depends on imported metallic/graphite plates, exposing EU value chains to risk. Composite BPPs (cBPPs) manufacturing is immature (long cycle times, high scrap rates, fragmented digital control). OEMs demand proven durability, certification-ready quality, and scalable, circular processes for both low- and high-temperature PEMFC. AIM-PLATES combines advanced forming, shaping with a ZERO-X digital backbone (digital twins, inline QA, adaptive control) under an SSbD framework, demonstrated on two complementary EU TRL7 pilot lines: Pilot 1 - thermoplastic/carbon - ultra-thin, high-performance, remanufacturable plates; Pilot 2 - bio-based thermoset/(graphite + biocarbon) - cost-effective, robust, renewable plates. Both lines target first-time-right, low-carbon manufacturing. Demonstrators in aviation (HT-PEMFC short stack) and road vehicle specifically light commercial vehicles (LT-PEMFC – primary; HT-PEMFC – early-use, short stacks) will prove manufacturability and integration, generate comparative datasets vs. incumbent solutions and de-risk adoption.The project spans seven work packages covering materials, processes, pilot-line development, the digital backbone, demonstrations, sustainability, standards road-mapping, skills, exploitation & market uptake, delivering new knowledge, validated industrial assets and an exploitation strategy aligned with NZIA, Clean Hydrogen JU SRIA, and Made in Europe. By 2030, AIM-PLATES will strengthen EU sovereignty in hydrogen technologies by reducing reliance on imported BPPs and fossil inputs, cutting CO2 per plate by up to 60%, and establishing replication pathways to electrolysers, flow batteries and other net-zero technologies, supporting circular, digitised, resilient value chains and Industry 5.0 skills in the EU.