TCL, a specialist in advanced thin film coatings is collaborating with Borit NV, a world-class manufacturer of sheet metal products and assemblies which has pioneered the exploitation of hydroforming of thin steel sheet for the efficient, low cost production of complex geometry structures for bipolar plates in fuel cells, electrolysers and other electrochemical devices. Coatings are essential to improve performance and to achieve longevity in order to meet the commercial constraints of mass-market hydrogen-economy devices, particularly in automotive and other consumer-focused applications. Ever stricter cost requirements will only be addressed by new strategies for serial production. Fundamental questions, including the feasibility of coating before forming as a more cost-effective approach than the coating of ready-formed plates, have been addressed in this pre-industrial research to identify these key issues and establish a sound platform for future collaboration.