Bipolar plates are among the key components of fuel cells, and their design with minimum thickness and weight plays an important role in improving overall system efficiency. Aluminum alloys are considered suitable candidates for this application due to their low density and good corrosion resistance; however, their limited formability at low temperatures poses challenges for conventional forming methods. In this study, a hot gas blow forming process is investigated for the fabrication of Archimedean spiral bipolar plates made of AA1050 aluminum alloy. For this purpose, a laboratory-scale hot gas forming system was designed and developed, and the effects of the main process parameters, including temperature, gas pressure, and forming time, on the channel filling depth were experimentally evaluated. The results indicate that increasing temperature has the most significant influence on improving formability and increasing channel depth, whereas gas pressure and forming time exhibit relatively smaller effects. The findings confirm the effectiveness of the hot gas blow forming process as a low-pressure and efficient method for manufacturing aluminum bipolar plates with complex geometries. Increasing the forming temperature from 200 to 400°C increased the forming depth by 3 times. Increasing the gas pressure to 20 bar increased the depth of the formed grooves by over 70%.