Font Size: 

This study presents a CFD-based analysis of bipolar plate flow field designs in proton exchange membrane fuel cells (PEMFCs) for heavy-duty vehicles (HDV). The investigation begins with a rigorous review of industrial stacks used in HDV applications, collecting data from different manufacturers regarding active area, operating pressures, and flow rates. Subsequently, three laboratory-scale models (25 cm² active area) will be created using CAD software (CATIA V5), with operating conditions derived from literature. CFD simulations are performed for hydrogen and oxygen under isothermal conditions (80 °C), focusing on velocity distribution, pressure drop, and Reynolds number to evaluate the advantages and limitations of serpentine, parallel, and pin-type channel configurations. Following validation at the small scale, all models will be scaled to an industrial active area (~250 cm²), and the implications of scaling on flow behavior and system performance will be analyzed. Additional simulations at the industrial scale will compare results with laboratory-scale findings, highlighting pressure losses and flow uniformity across different geometries.