This paper presents a five-step design methodology to generate designs of biomimetic structural components from topology optimization results. In step one, all material allocated by topology optimization is classified as either beam like structures or nodes to generate an auxiliary model consisting of preserved regions, cylindrical beams, and ball nodes, which is an abstraction of the original topology optimization result. In step two, the auxiliary model is exposed to the original boundary conditions in a finite element analysis. Then, internal forces, torsion, and bending moments in all beams of the auxiliary model are identified with respect to both of their ends. In step three, a database is used to find a suitable biomimetic beam for each previously analyzed beam in the auxiliary model. In step four, adapted nodes are designed to connect the biomimetic beams and preserved regions to generate an intermediate biomimetic component design. And in step five, a design iteration and a validation of the final design are performed. The design methodology allows for reproducible bio-mimetic component designs, a trackable and easily documentable component development process, and the possibility of automating the design process to ultimately save development costs when designing structural components.

Proton exchange membrane fuel cells (PEMFCs) represent today one of the most common types of fuel cells for mobility applications due to their comparatively high-power density, low operating temperature, and low costs. A PEMFC regularly consists of a stack of individual cells in which each consists of polar plates and a membrane electrode assembly. To achieve the best possible electric conductivity over the series connection of cells, the contact pressure in between the cells must be uniformly distributed over the cell area. This pressure is usually applied to the stack by end plates, which frame the stack and are clamped together by bolts, which are tightened by a defined torque. Typically, these end plates are made from bulk material with no or limited optimization. Looking at mobility applications, e.g., in aerospace, a fuel cell should ideally provide high efficiency at the lowest weight. Based on this assumption, this paper uses topology optimization varying the material as well as the design space to derive new design concepts for the end plates of a PEMFC. The designs are compared with respect to an even stress distribution to the fuel cell stack, the weight of the plates, and the manufacturability in the laser powder bed fusion process. The most promising design is manufactured and results in a weight decrease of 48% compared to previously used aluminum bulk plates. Finally, the optimized base plates are applied to a test cell and the performance is compared to their conventional counterparts, showing a 1% increase in electric stack power despite the lower mass.