Fraunhofer-Institut für Produktionstechnologie IPT
More power in a smaller space: Compact press system for manufacturing hydrogen components
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More power in a smaller space: Compact press system for manufacturing hydrogen components
The Fraunhofer Institute for Production Technology IPT in Aachen has developed an innovative and cost-effective press-system for bipolar plate production. The new technology has been designed for companies that want to enter the hydrogen market without having to make high investments in new machinery. Researchers at Fraunhofer IPT will be presenting the press at the Hydrogen Technology World Expo trade fair in Hamburg from October 21 to 23, 2025.
The Fraunhofer Institute for Production Technology IPT in Aachen has developed an innovative and cost-effective press-system for bipolar plate production. The new technology has been designed for companies that want to enter the hydrogen market without having to make high investments in new machinery. Researchers at Fraunhofer IPT will be presenting the press at the Hydrogen Technology World Expo trade fair in Hamburg from October 21 to 23, 2025.
Traditional press systems are massive all-rounders: Depending on the type of press, they weigh up to 1,000 tons and fill large production halls. Conventional presses can apply up to 3000 tons of pressing force to the workpiece. The range of parts that can be manufactured is correspondingly large: from large-format body components and structural components to filigree components made of thin sheet metal, such as those used in hydrogen systems.
Scalable drive technology
The drive systems in modern presses work with discrete force transmission to the progressive die tool via the press ram, using only a few bearing points. However, this requires large and rigid structures to distribute the force as evenly as possible across the tool. When forming thin sheet metal, commonly used for bipolar plates, industry requires a particularly high degree of accuracy with very low tolerances of less than 10 µm.
Simply well formed: a press without tools
Scientists at Fraunhofer IPT have now developed a new press that delivers high pressing force in a small volume: Its new "MatriXpress" measures just three meters in length and 1.80 meters in height. Weighing less than 10 tons, it is a lightweight among presses, promising a pressing force of up to 800 tons at 60 strokes per minute. Unlike large press systems, it does not require a tool with integrated guidance, because the mold insert – the embossing stamp – is mounted directly in the press without compromising the alignment of the tool halves or the accuracy of the forming result.
When developing the "MatriXpress," researchers at Fraunhofer IPT faced the challenge of applying force in a minimal amount of space. Their solution lies in a new kinematic system based on wedges guided by linear bearings. This distinguishes the "MatriXpress" from conventional, larger systems in terms of how both its motion control works and the way force is transmitted to the tool inserts.
Another advantage is that the modular design of the “MatriXpress” allows the drive units to be scaled flexibly, so that the press or tool size and specific press force can be adapted to the respective application.
Low machine costs
The purchase of a conventional press system involves high costs: When a company decides to purchase a press, it does so with the intention of keeping the system in operation for decades. The investment costs for large press systems amount to between three and five million euros. The Fraunhofer IPT's “MatriXpress” requires less than 10 tons of steel and, therefore, needs less than a fifth of the material – while delivering the same press force. This is accompanied by lower operating and maintenance costs and, due to the smaller footprint, lower space costs.
Entry into the hydrogen market
The compact and powerful “MatriXpress” offers companies low-threshold access to the hydrogen market. With lower investment costs, companies can start forming bipolar plates for fuel cells and electrolyzers and test new manufacturing concepts. The modular design can be flexibly adapted to different component geometries and production volumes. In addition, the small system is particularly suitable for use in flexible manufacturing systems and interlinked press lines. This makes the “MatriXpress” particularly attractive for start-ups and medium-sized companies that want to position themselves in this dynamically growing future market.
Prototype in Aachen
At the Hydrogen Technology World Expo, Fraunhofer IPT will be presenting the “MatriXpress” (patent-pending) concept to industry professionals for the first time. Once it has set up and extensively tested a prototype – by spring 2026 – Fraunhofer IPT plans to rapidly commercialize the technology with component and press manufacturers.
Visitors can find out more about "MatriXpress" and other research and development by Fraunhofer IPT in Hall 4, Booth 20 at the Hydrogen Technology World Expo, which takes place in Hamburg from October 21 to 23, 2025.
The scientists at Fraunhofer IPT developed the hybrid punching and forming machine as part of the " FRHY" research project. The project is funded by the Federal Ministry of Research, Technology, and Space (BMFTR) under grant number 03HY112B.
Fraunhofer Institute for Production Technology IPT
Steinbachstrasse 17 52074 Aachen Germany Phone +49 241 8904-0 is a constituent entity of the Fraunhofer-Gesellschaft, and as such has no separate legal status. Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Hansastrasse 27c 80686 München Germany www.fraunhofer.de info@zv.fraunhofer.de Editor: Susanne Krause M.A. Phone +49 241 8904-180 susanne.krause@ipt.fraunhofer.de