One way to increase the efficiency of a fuel cell in a car is to reduce the mass besides increasing the electrical power. The interior of a fuel cell consists of many stacks connected in series, consisting of individual layers. This project is concerned with analysing the individual layers and finding out how the mass of the individual stacks can be reduced to increase the efficiency of a fuel-cell-powered car. Weight plays a significant role in vehicle performance and range. Within this project, a fuel cell model was designed, and the following methods were used to save mass. The fuel flow plate was discussed as a potential layer for weight optimisation by determining the requirements, properties, and percentages of volume. One method that benefits weight saving is the substitution of materials. Continuously developed composite materials, such as the carbon fibre used in this project, predominantly exhibit improved properties. Another method was used to carry out a process that can be helpful in the further development of fuel cells. Software analyses were used to determine excess material, which could then be removed. For this purpose, simulations of operating situations were carried out, enabling maximum deformations and stresses of the component to be determined. Based on these results, an improved fuel flow plate was developed, whose properties were compared with the original one. The extremely low values of deformations and stresses finally produced unexpectedly high weight optimisation of up to 78.82% per fuel flow plate. The process carried out here shows excellent potential to further optimise existing fuel cells by replacing materials and changing shapes.
