Metal bipolar plates are key components in fuel cells that are considered as the best alternative to replace graphite plates. Material selection in bipolar plates depends on its weight and corrosion resistance. Metallic bipolar plate can be considered as the best alternative instead of graphite and composite plates. One of the new processes in order to produce this plat is gas blow forming process. In this study, forming of AA8111 bipolar plates with 200 µm thickness in concave groove dies is investigated by gas blow forming process at various pressures (20, 30 and40 bar) and temperatures (300 and 400 ° C). The filling percent of die at various wall angles and depth to width ratios are examined. According to the dimension of channels, maximum and minimum thinning percentage at high temperature and pressure are investigated. Results show that at wall angle of ∝=0, and the depth to width ratio of h/w=0.5, rupture occurs at pressure of 20bar and at temperature of 300° C and at pressures of 20 and 40 bar at temperature of 400° C. The best channel filling with lowest thinning obtained at ∝=15 and h/w=0.5.