{"id":32888,"date":"2025-03-25T10:54:47","date_gmt":"2025-03-25T09:54:47","guid":{"rendered":"https:\/\/www.zeltwanger.de\/?p=32888"},"modified":"2025-03-31T17:01:16","modified_gmt":"2025-03-31T15:01:16","slug":"leak-testing-as-a-service-for-bipolar-plates","status":"publish","type":"post","link":"https:\/\/www.zeltwanger.de\/en\/leak-testing-as-a-service-for-bipolar-plates\/","title":{"rendered":"Leak testing as a service for bipolar plates"},"content":{"rendered":"

From lab to fab \u2013 ZELTWANGER offers scalable test equipment for bipolar plates, battery cells & more<\/h2>\n

ZELTWANGER Leaktesting & Automation GmbH develops and manufactures solutions for leak testing of bipolar plates, fuel cell stacks, battery cells and packs, and much more. The T\u00fcbingen-based company also offers a testing service for these types of products, which can be used as a lean entry into series production.<\/strong><\/p>\n

The increasing popularity of vehicles with fuel cell and electric drives means that solutions for leak testing are also in greater demand. Because whenever hydrogen or electrolytes are used, tightness is an indispensable quality and safety feature. Two typical components are bipolar plates and battery cells. These are assembled into fuel cell stacks or battery packs and manufactured in large quantities.<\/p>\n

A wide range of companies are increasingly getting involved in electromobility to secure market shares in this growing segment. However, the leak tests required in the development and manufacturing process are a hurdle to begin with, as they require appropriate high-tech equipment and special expertise. This is why ZELTWANGER, a leading manufacturer of leak testing technology and its automation, has recently started offering the testing of prototypes and small series as a service. \u201cWe support our customers from lab to fab, i.e. from the first sample components to series production. Our Testing-as-a-Service offer enables them to evaluate the feasibility of their product. This drastically reduces costs and risk in the start-up curve,\u201d explains Jochen Kober, Industry Manager E-Mobility at ZELTWANGER. If the customer decides to launch the product, ZELTWANGER offers a scalable system concept for the independent continuation of the test processes. The test stations can initially be operated manually or semi-automatically and later, with increasing quantities, fully automatically and in a linked manner. The expert states: \u201cAfter validation in the prototype phase, there is no need for re-validation for series production. The test tool and process can be easily transferred to other systems.\u201d The service provided by the T\u00fcbingen-based company thus completely relieves the component manufacturer of the validation process.<\/p>\n

The test tool is the central component alongside the test station. It usually consists of an upper and lower part, and stamps may also be present. During the test procedure, both halves are pressed together, and at the same time the workpiece is subjected to the pressure of the test medium. Important: The tool must nestle exactly against the component from all sides to prevent deformations. All tool parts are therefore manufactured individually and with the highest precision.<\/p>\n

In addition, ZELTWANGER selects the appropriate test method for the customer. For simpler tests, for example, to obtain a rough indication of the welding result, efficient methods such as pressure change measurement using air are used. If, on the other hand, it is a matter of detecting the smallest leaks, test methods with tracer gases such as helium are used.<\/p>\n

With the latter, it is possible to detect leak rates of up to 1 x 10-6 mbar l\/s. In these regions, the mass spectrometer only counts individual molecules. The fact that such small amounts of the tracer gas find their way through the material is due to the production processes such as embossing or welding. These can cause the finest microcracks. In the case of graphitic bipolar plates, the base material can already have microcracks. Considering such small leakage quantities, the question of the reproducibility of the results is justified. \u201cFor reliable tests, it is important that no molecules of the tracer gas remain in the test system. This is a challenge that requires a lot of high-tech, but we have it well under control,” says Jochen Kober.<\/p>\n

Definition<\/h3>\n

Bipolar plates<\/strong>are key components in fuel cells and electrolyzers. They conduct the current between the cells and distribute the reactants hydrogen and oxygen. They also have a cooling function. Most bipolar plates are made of thin sheet metal or foil (stainless steel, aluminum alloys, titanium). Another material is graphite. The production of the metallic variants is carried out by traditional forming processes or hydroforming. The channels for gas distribution are also introduced, which give the plates their typical appearance. A bipolar plate consists of two halves, which are usually welded with a laser. The cooling medium later flows inside. The reactants flow along the channels on the outside.<\/p>\n

Footage<\/h3>\n

Figure 1: Example component of bipolar plate<\/p>\n

\"Bipolarplatte\"
ZELTWANGER tests all types of bipolar plates for fuel cells and electrolysis plants for leaks. High-precision test tools are specially manufactured for the complex components. The T\u00fcbingen-based company specifies the current maximum component size as 750 x 650 mm. Image: ZELTWANGER<\/figcaption><\/figure>\n

Figure 2: Testing facility, Jochen Kober<\/p>\n

\"Bipolarplatten
Jochen Kober, Industry Manager E-Mobility at ZELTWANGER in front of a station for leak tests: \u201cWe support our customers ‘from lab to fab,’ i.e. from the first sample components to series production.\u201d Image: ZELTWANGER<\/figcaption><\/figure>\n

Figure 3: Testing facility<\/p>\n

\"Bipolarplatten
ZELTWANGER leak test stations can be operated manually or be automated. They can also be linked. Image: ZELTWANGER<\/figcaption><\/figure>\n

About ZELTWANGER<\/h3>\n

ZELTWANGER was founded in 1982 in Du\u00dflingen near T\u00fcbingen as a manufacturer of mechanical engineering components. Today, the company consists of eight subsidiaries organized within a holding structure, with its headquarters in T\u00fcbingen. Additional locations are in the Czech Republic, the USA, and China. The company employs around 470 people worldwide, and its revenue amounts to approximately 81 million EUR (2023).<\/p>\n

ZELTWANGER currently focuses on three business areas: contract manufacturing, leak testing, and thermal management. In all these fields, ZELTWANGER is among the leading providers. A key aspect of the company\u2019s philosophy is fostering trustworthy partnerships and driving sustainable innovation together.<\/p>\n

Press contact<\/h3>\n

ZELTWANGER Holding GmbH
\nBenjamin Rilling
\nMarketing & Communications
\nJopestr. 3
\n72072 T\u00fcbingen<\/p>\n

Phone: +49 7071 3663119
\nE-mail: pr@zeltwanger.de<\/a><\/p>\n

 <\/p>\n

\n

Download Press Release<\/a><\/p>\n

Download Media Assets<\/a><\/p>\n<\/div>\n","protected":false},"excerpt":{"rendered":"

ZELTWANGER offers leak testing of bipolar plates and battery cells as a service for prototypes and small batches \u2013 with processes that can be transferred to scalable systems for series production at the customer site.<\/p>\n","protected":false},"author":21,"featured_media":32962,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[92],"tags":[],"class_list":["post-32888","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-press-releases"],"acf":[],"yoast_head":"\nLeak testing as a service for bipolar plates | ZELTWANGER<\/title>\n<meta name=\"description\" content=\"ZELTWANGER offers leak testing of bipolar plates and battery cells as a service for prototypes and small batches \u2013 with processes that can be transferred to scalable systems for series production at the customer site.\" \/>\n<meta name=\"robots\" content=\"index, follow, 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