ENERGY & BATTERIES
Battery Manufacturing
At Gigafactory Scale
The EV revolution runs on batteries—and battery manufacturing demands automation precision that few industries can match. Micron-level accuracy. Cleanroom compatibility. Cells that can't tolerate damage.
CHALLENGES WE SOLVE
Battery Manufacturing Challenges
PRECISION REQUIREMENTS
Precision Requirements
Battery cells must be placed with sub-millimeter accuracy. Misalignment causes thermal issues and safety risks.
OUR APPROACH
Servo-driven systems with vision guidance. Force-controlled insertion. Verification at every step.
Handling Sensitivity
Lithium cells can't tolerate impact, pressure, or contamination.
APPROACH
Custom EOAT designed for your cell format. Controlled grip force. Clean, non-marring surfaces.
High-Volume Production
Gigafactories produce millions of cells. Automation must run 24/7 and scale to ambitious ramp targets.
APPROACH
Robust design, predictive maintenance, support contracts that keep you running.
SAFETY CONSIDERATIONS
Safety Considerations
Battery manufacturing involves hazardous materials and thermal runaway risks.
OUR APPROACH
Proper safety system design. Emergency response integration. NFPA compliance.
APPLICATIONS
Battery Manufacturing Applications
Cell Manufacturing
Electrode stacking, winding, electrolyte filling, and formation.
Module Assembly
Cell-to-module assembly with precision placement and welding.
Pack Integration
Module-to-pack assembly, BMS integration, and EOL testing.
Quality & Testing
In-process testing, vision inspection, and data collection.
Material Handling
Automated cell transport, sorting, storage.
PRECISION ENGINEERING
Accuracy That Battery Manufacturing Demands
Sub-millimeter accuracy for cell-to-module assembly
Precise insertion force monitoring prevents cell damage
Every cell verified before and after placement
CASE STUDY
Battery Module Assembly Cell
Samsung SDI — MichiganOur Solution
- FANUC robot cell with custom vacuum EOAT
- Vision-guided cell placement (±0.05mm)
- Force-controlled insertion monitoring
- Integration with MES for full traceability
- Cleanroom-compatible design throughout
RESULTS
- Placement accuracy: ±0.03mm (exceeded spec)
- Throughput: 12 cells/minute achieved
- Cell damage rate: <0.01%
- Traceability: 100% cell genealogy
Running 24/7 for 8+ months
Zero unplanned downtime
"iAutomate delivered a turnkey solution that exceeded our specifications."
— Process Engineering Manager, Samsung SDITechnologies We Deploy
Robots
- FANUC
- ABB
- KUKA
- Yaskawa
PLCs
- ControlLogix
- CompactLogix
- S7-1500
Vision
- Cognex
- Keyence
- SICK
Safety
- GuardLogix
- Pilz
- Banner
OUR SERVICES
Energy & Battery Automation Services
Robot Programming
Precision cell handling, module assembly, pack integration.
Learn MorePLC Programming
Formation control, BMS integration, process automation.
Vision Systems
Cell inspection, placement verification, defect detection.
Learn MoreControls Integration
Safety systems, thermal monitoring, environmental controls.
FAQ
Frequently Asked Questions
Yes. We have experience with all major cell formats.
Yes. Our engineers follow proper protocols for controlled environments.
Our servo-driven systems routinely achieve ±0.05mm or better.
Absolutely. Full traceability from cell to pack is standard.
Ready to Scale Your
Battery Production?
Precision automation for battery cell, module, and pack manufacturing.
