A method for forming a fuel cell assembly including the pre-final-assembly
step of forming a plurality of fuel cell sub-assembly modules, each
module including a predetermined number of individual fuel cell repeating
units, for example, ten. Each module may be leak and performance tested
and certified prior to inclusion in the final fuel cell stack, thus
limiting potential rework to only an individual module and only before
assembly of the final stack. Preferably, each module is assembled on an
assembly fixture having alignment rods, using a combination of resilient
gasketing and RTV to seal between the elements. The assembled module is
then placed under compression while the silicone is cured.