Holoss - Project AIM-PLATES

Project: AIM-PLATES - AI-Enhanced Sustainable Manufacturing of Composite Bipolar Plates for Cross-sectoral Net-Zero Technologies

Start: 01/06/2026 End: 31/05/2030

Project website: To be confirmed

This project has received funding from the European Union’s Horizon Europe programme under Grant Agreement No. 101294046.

DESCRIPTION: Europe’s climate-neutral transition requires the rapid and cost-effective deployment of Proton Exchange Membrane Fuel Cells (PEMFCs), yet bipolar plates remain one of the greatest technological and economic bottlenecks, accounting for approximately 80% of stack weight and 40% of total cost. AIM-PLATES addresses this challenge by developing next-generation composite bipolar plates through advanced manufacturing technologies integrated with the ZERO-X digital backbone, including digital twins, inline quality assurance and adaptive process control under a Safe and Sustainable by Design (SSbD) framework. The project will demonstrate two complementary TRL7 pilot lines: one producing ultra-thin, high-performance and remanufacturable thermoplastic/carbon plates, and another manufacturing cost-effective bio-based thermoset plates reinforced with graphite and biocarbon.

Demonstrators for aviation and light commercial vehicles will validate manufacturability, durability and industrial integration while generating comparative performance data against current solutions. Through seven interconnected work packages covering materials development, advanced manufacturing, digitalisation, sustainability assessment, standardisation, skills development and market uptake, AIM-PLATES will strengthen European leadership in hydrogen technologies. By 2030, the project aims to reduce dependence on imported bipolar plates and fossil-based materials, decrease CO₂ emissions per plate by up to 60%, and establish scalable, circular and resilient manufacturing pathways applicable to fuel cells, electrolysers, flow batteries and other net-zero technologies.

HOLOSS ROLE:

HOLOSS ensures alignment with the Safe and Sustainable by Design (SSbD) principles and safety compliance of the materials and manufacturing processes developed within the AIM-PLATES innovations.

HOLOSS conducts a comprehensive Life Cycle Sustainability Assessment (LCSA) of the proposed production processes, integrating Life Cycle Assessment (LCA), Life Cycle Costing (LCC) and Social Life Cycle Assessment (s-LCA).

HOLOSS performs the Techno-Economic Assessment (TEA), providing guidance to improve economic feasibility, accelerate market adoption and identify technological and industrial bottlenecks.

HOLOSS leads the Circularity and End-of-Life Strategy together with a holistic sustainability assessment, developing improvement strategies including design-for-remanufacturing and the use of recyclable and recycled materials.