This thesis addresses the development of a manufacturing process for assembling a five-layer membrane electrode assembly (MEA) for a proton exchange membrane fuel cell. The starting point is an existing laboratory procedure in which the aligned assembly is transferred from an FDM template to a hot press, which can cause misalignment and warping of the lamination foils, as well as the formation of air bubbles. These defects result in a reduction in the active area of the MEA. To improve the process, a two-part aluminum positioning fixture with guide pins and integrated temperature measurement during lamination was designed and manufactured using CNC machining. Integrated temperature measurement contributes to greater process repeatability and traceability. Comparison with the existing procedure showed improved foil alignment and fewer defects, such as warping and air bubbles. The new MEAs were electrochemically analyzed, and the results were compared with those of existing MEAs. The results show that the new template reduces the loss of active area caused by misalignment.
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