Charged EVs | LEAD unveils high-precision solid-state battery cell stacking machine

LEAD has released of an integrated solid-state battery cutting and stacking machine targeted at addressing the technical challenges of next-generation energy storage manufacturing. The machine is engineered for the specific requirements of solid-solid interface materials used in all-solid-state batteries, which require highly precise and controlled stacking due to their sensitivity and brittle nature.

The new system addresses issues associated with aligning and stacking layers of solid electrolyte materials such as oxides, sulfides and halides. These materials are highly sensitive to moisture and air, demanding ultra-dry, sealed environments to prevent degradation or hazardous gas release. Their brittleness necessitates specialized pressing and handling during high-speed production and consistent, high-precision alignment is essential to avoid voids, short circuits and micro-damage.

LEAD says that its machine achieves ±0.15 mm alignment accuracy through high-speed vision-based positioning and platform correction. A dual-loop pressure and displacement control maintains uniform interlayer contact to avoid indentation and damage. The machine’s biomimetic suction system is designed to handle fragile separator and electrode sheets at high speed without causing surface defects.

For mass-production suitability, the machine integrates framing, cutting, and stacking into a single system, reducing transfer time and enabling throughputs greater than 0.35 seconds per piece. Its modular design supports varying battery sizes from 100 to 700 mm in length, 80 to 150 mm in width, and 1 to 30 mm in thickness, allowing compatibility with a wide range of solid-state cell formats.

The system includes intelligent, closed-loop control features such as dust and hazardous gas monitoring, dew point measurement for microsecond-level contamination alerts, and real-time vision-based defect inspection. Predictive maintenance is enabled through a built-in PHM (prognostics and health management) system, while an ergonomic human-machine interface is expected to improve overall equipment effectiveness and reduce operating costs, according to LEAD.

Source: LEAD