Formed and welded metal PEM fuel cell bipolar plates are the most prominent strategy to reach low cost and high performance in a high volume production environment. Using the proprietary coil-based Hydrogate proces, Borit is able to achieve world class thin sheet metal forming with excellent repeatability and reproducibility. An overview of the typical process flow for metal bipolar plate production, process capabilities and yields will be shown. Implementing the appropriate process controls overcomes the challenges related to laser welding of thin metal foils with constraints regarding plate flatness, leak tightness and weld strength. An update on the latest developments will be presented, together with the related QC and traceability efforts.