Battery Cell Prototyping

In just six months, we finished developing prototype battery cells with a 46x diameter for dual-use applications through a two-phase project that met every customer requirement.

Phase One: Chemistry Enhancement and Local Supply Chain Integration

The initial phase concentrated on advancing the battery cell formulation to align with the customer’s cylindrical cell requirements. This process included updating the battery cell chemistry and transitioning to the use of a European supply chain for both active and non-active materials, including cathodes, anodes, electrolytes, and carbon additives.

The project commenced at our Berlin battery application laboratory, where we utilised a Design of Experiment (DoE) methodology. Our technical team developed a comprehensive plan to refine the battery cell chemistry according to the customer’s needs. Through our high-throughput internal testing, we systematically optimised cell formulations using various combinations of European-sourced materials. Multiple experimental cycles were carried out to identify the most effective material cell configurations for the subsequent prototyping phase of 46x diameter cylindrical battery cells.

Phase two: Transition to Large Cylindrical Battery Cell Prototyping Partner in Asia

Upon identifying the optimal battery cell formulation, battery cell prototype production was initiated. Supported by our local expert team in Asia, we manufactured battery cell prototypes utilising the refined cell formulation determined during laboratory trials. The assembly of those large cylindrical battery cells was overseen by our local experts. The final steps, including electrolyte filling and cell formation, were subsequently completed at our Berlin facility.

Customer Satisfaction and Battery Cell Performance Assessment

Each battery cell prototype underwent thorough inspection and performance testing at our Berlin site, assessing cycle life, stability, and capacity under varying conditions. All units surpassed customer expectations, leading to the launch of a new project for small-series supply of these advanced battery cells with the updated chemistry.

If you would like more information about our cell prototyping capabilities, please reach out to us directly.