Flow field configurations in PEMFCs: Design, Modeling, and performance insights

Proton exchange membrane fuel cells (PEMFCs) are a promising clean energy technology due to their high efficiency, zero emissions, and applicability in transport and stationary systems. Despite these advantages, large-scale commercialization is constrained by challenges such as water management, thermal control, material costs, and limited durability. Among PEMFC components, the flow field is critical in ensuring uniform reactant distribution, efficient water and heat removal, and effective current collection. To overcome these limitations, this review systematically examines the evolution of flow field designs, from conventional geometries (serpentine, parallel, interdigitated) to advanced configurations, including biomimetic, baffle-based, porous media, composite, and three-dimensional structures. Key design parameters such as channel shape, curvature, aspect ratio, rib-to-channel ratio, and tapered depth are analyzed for their impact on performance metrics, including power density, gas diffusion, and water evacuation. The review further addresses recent advances in bipolar plate materials and fabrication methods, such as metallic, polymeric composite, and graphite structures. It highlights the role of computational fluid dynamics (CFD), AI-assisted design, and multi-objective optimization in guiding performance improvements. By integrating experimental insights, simulation-based optimization, and emerging design strategies, this review provides a holistic framework to guide the development of high-performance, durable, and cost-effective PEMFC systems.