Fuel cell manufacturing: An introduction to opportunities and challenges

Recent events have lead to surging interest in alternative energy sources and their utilization. One example is the fuel cell. Fuel cells are seen as clean energy sources for a number of applications, including automobiles and power supplies for homes. As a result, there are significant research efforts being made to develop fuel cells and to improve their competitiveness in cost per kilowatt compared to more conventional energy sources. In addition, if fuel cells are to be used in high volume products, they must be manufactured efficiently and in quantity. This situation presents opportunity for both professionals and educators in the manufacturing field. Currently, fuel cells are low volume products that are often built to order, with resulting higher costs and longer lead times. Many of the key components of fuel cells are not made using high production techniques. Successful evolution of the fuel cell industry requires production research and the application of modern manufacturing principles, as well as a supply of graduates from manufacturing programs in which these principles have been emphasized. This paper introduces readers to some aspects of fuel cell manufacturing impeding efficient production. A brief description of proton exchange membrane (PEM) fuel cell technology, components, and the current state of the art of their manufacture are presented. Educational challenges and specific efforts to address them currently underway within in the College of Technology and Applied Sciences (CTAS) at Arizona State University (ASU) are discussed. An annotated bibliography related to fuel cell manufacturing is also included as an aid to others interested in the topic.