Fuel cell and electrolyzer assembly involves stacking multiple components like bipolar plates and membranes. Manual processes often lack precision, leading to defects such as leaks and poor performance. As the demand for clean energy grows, manufacturers need scalable and automated testing solutions to maintain fuel cell quality and increase production volumes.
We provide advanced testing solutions to ensure the reliability and performance of fuel cells for electric vehicles and grid storage. We help manufacturers evaluate peak power, durability, and environmental factors, preventing overheating and ensuring each component meets the highest standards. Through rigorous testing, including leak detection and electrical evaluation, our automated testing systems reduce defects, improve efficiency, and support scalable production. This drives higher customer satisfaction and strengthens market competitiveness.
Customer Challenges
Reducing defects and inconsistencies in manual fuel cell assembly to improve product quality.
Lowering costs of materials and labor in assembly processes.
Automating fuel cell assembly to scale production from lab to low volume to full production while enhancing product quality.
Conducting environmental testing to ensure fuel cells perform optimally under various temperature conditions.
Implementing rigorous safety measures, such as intrinsically safe wiring and proper grounding, to protect workers from the risks of handling hydrogen and other fuel cell materials.
Every testing project is unique. Allow us to listen to your challenges and share how automation can launch your project on time.
Our Testing Capabilities
We work with manufacturers to establish hydrogen fuel cell and electrolyzer testing needs and deliver automated test systems that are tailored to a customer’s application and assembly production requirements.
Proof of Principle (PoP) Testing
Conduct PoP testing to validate the feasibility of fuel cell technologies and assembly processes, ensuring they meet desired performance criteria.
Peak Power Performance Testing
Measure peak power performance to assess the efficiency of fuel cells by determining how much electricity is generated from a given amount of hydrogen and oxygen.
Durability Testing
Evaluate long-term fuel cell performance, measuring heat generation, pressure, and flow characteristics, ensuring fuel cells withstand extended use.
Leak Testing
Confirm assembled fuel cells are free from leaks, maintaining safety and performance integrity.
Customer Benefits
High-Quality Assurance
Ensure that assembled hydrogen fuel cells and electrolyzer meet the highest quality standards.
Cost Savings
Testing reduces defects and waste and improves operational efficiency.
Comprehensive Support
End-to-end support, from initial design and analysis to installation, commissioning, and ongoing maintenance.
Scalable & Flexible Platform
Testing software and hardware that can evolve with the product and business needs.
In-Process Fuel Cell and Electrolyzer Testing
In-process testing allows manufacturers to detect and correct inconsistencies in components and sub-assemblies during fuel cell and electrolyzer assembly. We use advanced testing methods to catch issues early, optimize manual assembly and prevent defects. These tests include vision inspection for bipolar plate quality, press force measurements for proper component compression, and leak testing to identify faults.
By addressing issues before final production, we help reduce waste and enhance product quality.
Fuel Cell In-Process Testing Methods
- Vision inspection
- Press force
- Leak test
- Fuel cell module test
- Gage test
- High Potential (Hi-Pot)
End-of-Line Fuel Cell and Electrolyzer Testing
End-of-line testing ensures the quality and performance of each fuel cell and electrolyzer before delivery. We conduct a range of tests to verify that each unit meets the required specifications and standards. These include peak power performance testing to measure maximum electricity output, durability testing to assess performance over extended periods of operation, and leak testing to detect potential safety or efficiency issues.
By implementing rigorous end-of-line testing, we ensure every fuel cell and electrolyzer is reliable, efficient, and ready for deployment in transportation or grid energy applications.
Fuel Cell End-of-Line Testing Methods
- Current monitoring
- Differential flow
- Differential pressure
- Direct current internal resistance (DC-IR)
- Flow – Air
- Flow – Fluid
- High Potential (Hi-Pot)
- Helium Mass Spectrometry (HMS)
- Leak Test
- Mass Flow
- Power Measurement
- Pressure
- Pressure Decay
- Relative Humidity
- Resistance
- Temperature
- Vacuum Decay
- Voltage
