METHODS FOR MAKING TAILORED PERMEABILITY FUEL CELL BIPOLAR PLATES

Methods are provided for designing a microchannel layout for a flow field of a bipolar plate. The methods include defining a fluid flow optimization domain with boundary conditions and loads. Using a gradient-based algorithm together with computational fluid dynamics, the domain is then optimized for minimum flow resistance. The methods include setting the minimum inverse permeability to a non-zero value, and obtaining a grayscale design and fluid velocity field. Using Gray-Scott reaction diffusion equations with the grayscale design and fluid velocity field, the method includes obtaining a microchannel layout. The microchannel layout is then incorporated as a pattern for the flow field of the bipolar plate. In various aspects, anisotropic microchannels are provided; they may be formed using at least one of an additive manufacturing technique, a metal inverse opal electroplating technique, and a hybrid combination thereof.