This presentation will present the results of the mass-production cost estimation project that Directed Technologies (DTI) has done for the Department of Energy. DTI has developed a strong framework to assess the cost and likely manufacturing methods of future fuel cell components. DTI estimates are based on 80kW direct hydrogen Polymer Electrolyte Membrane (PEM) fuel cells, and examine three different technology levels; a current system, and technology projections out to 2010 and 2015. These three system designs are examined at five different production levels, ranging from 1000 to 500,000 vehicles per year.

Cost estimation at very low manufacturing rates (1000 units/year) presents particular challenges as traditional low cost mass manufacturing methods are not cost effective due to high per-unit setup and tooling costs. For repeat parts like the Membrane Electrode Assemblies (MEAs) and the flow plates, many are needed for each system, so even at 1000 systems/year, hundreds of thousands of parts are needed. But for items such as end plates and current collectors, the small production rates can make mass-manufacturing techniques rather cost-ineffective. Consequently, considerable thought has been given to manufacturing methods and potential system design changes at these low manufacturing rates.

The presentation will describe the cost computation methodology, provide definition and component performance metrics for each of the three systems (current, 2010, and 2015), and provide subsystem and total cost estimates for each system from low to high manufacturing rates. Conclusions and major findings will be summarized regarding key results and assumptions. Manufacturing methods and cost sensitivities will be discussed. Overall, a comprehensive forward looking picture of an entire fuel cell system and its cost will be presented.