Plug Power is a world leader in fuel cell stack and fuel cell systems manufacturing, with over 50,000 fuel cells in the field for materials handling and stationary power applications. Plug Power is using this success to develop new markets in range-extenders for delivery vans, heavy duty vehicles, and aerospace. The rapid growth of Plug Power’s fuel cell technology has brought new challenges with high volume manufacturing. An individual cell needs to be made in less than 5 seconds, and then sealed and stacked rapidly and reproducibly.

This talk will review some of the general approaches that Plug Power is taking toward high-volume stack manufacturing. We will also review two programs funded by the U.S. Department of Energy on high volume manufacturing, and novels ways toward low cost, high volume manufacturing.