ENGEL: Injection-moulded plastic cell frames for industrial electrolysers
- ENGEL operates trial machines with clamping forces up to 55,000 kN to evaluate large-format electrolyser cell frames.
- Materials under consideration include PPS, PSU, PPSU and PEEK, with KOH exposure and glass-fibre reinforcement identified as critical durability issues.
- Injection compression moulding (coining) and precise platen parallelism control are highlighted to reduce warpage and improve dimensional stability.
- Sealing may shift from separate assembly to integrated or automated post-moulded solutions, but material compatibility and long-term durability must be validated.
Overview
Electrolyser cell frames are critical, large-format components that support stack design, media guidance, sealing and mechanical stability as systems move from prototype to industrial production. Injection moulding offers repeatability, design freedom and potential cost efficiency for series production, but requires coordinated work on material selection, part and mould design, machine technology and process development.
Materials and chemical durability
High-performance thermoplastics under evaluation include PPS, PSU, PPSU and PEEK. Alkaline environments (e.g., KOH) can attack glass-fibre reinforcement; designers must limit continuous fibre paths so degradation is confined to a shallow surface layer while maintaining core structural integrity.
Process and machine technology
Large, flat cell frames demand control of warpage and dimensional accuracy. Injection compression moulding (coining) can improve flatness, while precise platen parallelism—enabled by ENGEL’s duo platform and tie-bar adjustment—plus stable plasticising and process monitoring support consistent quality over long runs.
Trials, moulding and integration
ENGEL’s trial and application centres let customers test materials, moulds, machine concepts and process strategies under near-series conditions. Mould design, gating, cooling, venting and automation are integral to achieving scalable, repeatable production.
Sealing and functional integration
Sealing remains a key function; future concepts may include post-moulded sealing, automated gasket handling or multi-material approaches, but all require careful validation of compatibility, adhesion and durability.
Source: Engel
