Innovation - KNIPPING Kunststofftechnik

Technology
for a better future.

With our own research and development department, we create groundbreaking solutions for the challenges of tomorrow.

Product Development

Our product development brings together all steps from concept to market readiness under one roof. Starting with idea generation, feasibility studies, and prototype construction, to industrialization and quality assurance, we cover the entire development process. In close collaboration with research partners and suppliers, we develop solutions that are both innovative and reliable.

Ein Mann mit Brille betrachtet ein Kunststoffbauteil vor einem Bildschirm mit einem digitalen 3D-Modell desselben Bauteils in einem Büro.

An example of this innovative strength is KNIPPING NEW MOBILITY with our humidification solution for fuel cells. This humidifier was fully designed, tested, and optimized in our own development department to meet the demands of modern hydrogen technology. From simulation to validation and series production, every step reflects our expertise and commitment to advancing sustainable and future-oriented technologies.

Design, Construction & Simulation

Our product development brings together all competencies to create highly advanced solutions for all industries – from initial planning and design to comprehensive simulation. Using state-of-the-art CFD, FEA, and Moldflow methods, we ensure that our components are designed for maximum efficiency and durability.

Our expertise goes beyond the development of humidifiers and also includes other BoP components for the cathode side.

Prototyping

Innovative concepts are realized in our prototyping department at KNIPPING – from the initial idea to the finished component. This allows for early testing, concept evaluations, feasibility studies, quick feedback, and technical iterations, accelerating product development.

Workstations:

Incoming goods inspection
Material storage
Preparation of distribution plates
Membrane/seal cutting and preparation
Stacking and encapsulation
End-of-line testing
Packaging and outbound

Testing & Validation

Pilot Plant

Our pilot plant, which will be operational from mid-2025, is an important step towards automated mass production. It allows us to flexibly produce and scale innovative products, such as the humidification solution, with a capacity of up to 5,000 units per year. The plant includes automated processes such as membrane sandwich manufacturing, stacking processes and end-of-line tests, ensuring the highest quality and efficiency while maintaining strict cleanliness standards.

Well-connected in Research.

Our research is driven by the continuous search for new materials and technologies that advance the future of fuel cell technology. Through intensive collaboration with renowned research institutions and international partners, we constantly expand our knowledge and develop solutions that meet the highest quality and efficiency standards. At the core of our work is the optimization of thermoplastic applications for a wide range of forward-looking applications.

An outstanding example of our research is KNIPPING NEW MOBILITY, our humidification solution for PEM fuel cells. Through collaboration with Esslingen University of Applied Sciences and other experts in the manufacturing process, we have made targeted progress in quality and performance, taking our humidification technology to a new level. This ensures that our developments not only meet current requirements but also set forward-thinking standards.

Institut für nachhaltige Energietechnik und Mobilität (INEM)

Labor für Kunststofftechnik (LKT)

Mikroskop im Vordergrund mit Studierenden im Hintergrund in einem Labor oder Klassenraum. Die Szene ist in eine organisch geschwungene, türkis umrandete Form eingebettet.

Schematische Darstellung eines Flachmembran-Befeuchters im Gegenstromprinzip: zeigt Gehäuse, Polymermembran, Ein- und Auslassports sowie optionale integrierte Komponenten wie Bypass, Sensorik und Wasserabscheider.

KNIPPING NEW MOBILITY

Humidification solution for Fuel Cells

KNIPPING NEW MOBILITY was founded in 2021 to develop balance-of-plant components for the cathode subsystem of PEM fuel cells. The initial focus of KNIPPING NEW MOBILITY is on the development and production of an air humidifier, leveraging the 60 years of experience of KNIPPING KUNSTSTOFFTECHNIK. KNIPPING NEW MOBILITY consists of experts with extensive experience in the fields of e-mobility, fuel cells, particularly humidification, and system integration.

Fuel Cell Humidifiers at a glance

The KNIPPING humidifier is a passive component, meaning it does not contribute to the parasitic losses of the fuel cell system. It utilizes the water generated in the fuel cell stack through the electrochemical reaction. This water exits the fuel cell in the form of vapor and/or droplets with the exhaust air. Separated by a polymer membrane, the dry inlet air and the moist exhaust air of the fuel cell are guided past each other in the humidifier. This membrane allows the transfer of water through diffusion but prevents the mixing of the inlet and exhaust air.

The result: A compact, sustainable, and practical solution that reduces overall operating costs in the long term. It offers the following advantages:

High moisture transfer
Low pressure losses
Polymer distribution plates in counterflow configuration
Flexible housing design
High product reliability

Integrated Solutions: Humidification System

Our humidifier seamlessly integrates adjacent BoP components upon request, such as by-pass with throttle valve, water separator, sensors, drainage, and shut-off valves. This thoughtful design allows for a space-saving and efficient solution for the fuel cell system. The resulting benefits include:

Significantly reduced space requirements due to the compact design
Reduced component costs, as pipe and hose fittings are eliminated
Simplified integration into the fuel cell system thanks to the optimized structure

Schematische Darstellung eines Befeuchtersystems für Brennstoffzellen

Model Kit for Humidifier Kit

Our innovation is based on the SMALL distribution plate format, which offers maximum flexibility in positioning the screwable inlet and outlet ports. Optionally, the ports can be adapted in shape to meet specific requirements. For applications up to 75 kW, we use a single stack, while for 75 to 150 kW, a double stack in “In Line” or “Parallel” configuration is used. This ensures efficient adaptation to varying power requirements and provides an optimal solution in the field of fuel cell technology.

Request now

“Off-the-Shell” SMALL

75kW

150kW

200kW

Customer SPECIFIC

75kW

150kW

200kW

Vielfältige Einsatzmöglichkeiten neuer Mobilitätsformen: Ein Flugzeug, ein Frachtschiff und ein Lastwagen symbolisieren unterschiedliche Verkehrsträger. Die Szene ist in eine organisch geschwungene, türkis umrahmte Form eingebettet.

Versatile Applications

Our industry-leading humidification solution for fuel cells enables the successful commercialization of hydrogen fuel cells across a wide range of applications:

Commercial vehicles
Public transportation
Rail transport
Shipping
Automotive
Off-highway
Aerospace
Stationary applications