This paper presents the results of research on novel methods for the manufacturing of metallic gas flow, bi polar plates (BPP) for use in proton exchange membrane fuel cells (PEMFC). Low cost, high speed, additive manufacturing methods that combine thermal spray (TS) and 3D printing (3DP) technologies are described. Flow plates were manufactured by creating 3DP patterns then depositing material with TS, and finally releasing the newly formed part. This net-shape spray forming method yields dense metal plates with interesting options for material choices and complex designs.