The bipolar plates are in weight and volume the major part of PEM fuel cell stack, and also a significant effect to the stack cost. To develop the low-cost and low-weight bipolar plate for PEM fuel cell, we have developed a kind of cheap expanded graphite plate material and a production process for fuel cell bipolar plates. The plates have a high electric conductivity and low density, and can be stamped directly forming fuel cell bipolar plates. Then, 1 and 10 kW stacks using expanded graphite bipolar plates are successfully assembled. The contact resistance of the bipolar plate is investigated and the electrochemical performances of the fuel cell stacks are tested. Good fuel cell performance is obtained and the voltage distribution among every single cell in the stacks is very uniform. (c) 2006 Elsevier B.V. All rights reserved.