30 Years of Fuel Cell Stack Product Development

Fuel Cell Stack Product Development services at Ballard cover a diverse number of activities ranging from the research, design and manufacture of individual fuel cell components to full stack and system development programs.

We have the people, products, facilities and technical expertise to serve a broad and diverse customer base, including small design firms and large global manufacturers.

From concept until delivery of the final product to your end customer, Ballard can help you make informed decisions, streamline your product development process and accelerate your time to market.

  • Membrane Electrode Assembly (MEA) formulation and integration of new and novel materials
  • Bi-polar plate design and manufacture using expanded graphite, metal and molded graphite
  • Bi-polar plate and MEA sealing concepts using thermoplastics, adhesives and liquid injection molding
  • Simulation and modeling to allow for investigation of a wide range of scenarios at the component, stack and system level
  • Feasibility and trade-off studies related to performance, operating without CVM, freeze start, durability, cost and power density
  • Focus on specific markets including; automotive, aerospace, military, portable. UAVs…


 SITUATION: Volkswagen approached Ballard for expertise and resources in support of advancing the automakers' fuel cell automotive research program.
 SOLUTION: In March 2013, the companies signed a 4-year TS contract to support the current fleet of VW HM demonstration cars, as well as design and manufacture of next generation fuel cell technology. Ballard engineers are supporting critical areas of fuel cell product design – including the membrane electrode assembly, plate and stack components – along with testing and system integration work.
 RESULTS: A collaborative working relationship has quickly developed between the Ballard and Volkswagen teams, permitting rapid progress and resulting in world leading stack technologies. Successful ongoing execution of the TS contract has led to the landmark transaction in 2015 for the transfer of certain automotive-related fuel cell IP and extension of engineering services