Industrial battery cell assembly dry room with robotic arms and module fixtures in a precision manufacturing environment
Formation Cycler
● ACTIVE — 847 packs
Dry-Room RH
≤ 0.1% — Nominal
Weld Inspection
US Inline — 100%
UN38.3 · UL 9540A · IEC 62619 Certified

Your cells. Our architecture.
One serial number
from chemistry to crate.

Robotic cell assembly, ultrasonic weld inspection, and full-stack BMS integration — purpose-built for EV startups, energy-storage integrators, and industrial fleet OEMs.

< 3ppm
Defect Rate
47 s
Cycle Time / Module
100%
Ultrasonic Inspection
18+certs
Compliance Coverage
Scroll to enter
Factory Walk-Through

Five stages. Every tolerance
measured in microns.

Each card is a live comparison between building in-house and running on our line. The numbers count up when you arrive — because data earns the click, not copy.

Stage 01

Cell Sourcing

Cathode Chemistry to Goods-In
01

We qualify cells from CATL, Samsung SDI, and LG ES to your voltage window and cycle-life spec, then incoming-inspect every lot against IEC 62660.

MetricYour In-HouseCell Line
Incoming Inspection% lots40–60%100%
Supplier MOQ Leverageunits5,000500
Chemistry Qualificationweeks8–122
Traceability Depthlevels26
Stage 02

Module Welding

Laser Weld + Ultrasonic Inspection
02

6-axis robotic placement to ±0.05 mm, fiber-laser busbar welding at 2 kW, and 100% inline ultrasonic inspection for weld integrity — every joint logged to serial.

MetricYour In-HouseCell Line
Placement Accuracymm±0.3±0.05
Weld Defect Rateppm120–350< 3
Cycle Time / Modulesec18047
Inspection Coverage%15100
Stage 03

BMS Integration

Firmware Flash + Functional Validation
03

We integrate and flash your BMS firmware (or our reference design), run cell-balancing validation, CAN/SMBus protocol tests, and thermal runaway simulation per UL 9540A.

MetricYour In-HouseCell Line
FW Flash Timemin224
Protocol Test Coverage%55100
Thermal Runaway SimincludedNoYes
BMS NRE CostUSD$85K$0
Stage 04

Pack Enclosure

IP67 Housing + Thermal Interface
04

Aluminum extrusion or stamped-steel enclosures with phase-change TIM at 4.5 W/m·K, IP67 sealing, and vibration isolation qualified to IEC 62619 shock/vibe profiles.

MetricYour In-HouseCell Line
Thermal InterfaceW/m·K1.5–2.04.5
IP RatingclassIP54IP67
Enclosure Lead Timeweeks143
Cost / EnclosureUSD$340$185
Stage 05

EOL Testing

Formation Cycling + Final Certification
05

Every pack completes a full formation cycle on our Maccor cyclers, passes a 48-point functional test, and ships with a serialized test report traceable to your customer's SN.

MetricYour In-HouseCell Line
Formation Cyclescycles1–23
Test Points / Packpts1248
Cert Report IncludedNoYes
Cost-per-kWh DeltaUSDBaseline−$14
Bottom Line
−$14 per kWh.
97% fewer weld defects.

Across 500 to 50,000 packs annually, our line consistently beats in-house assembly on defect rate, cycle time, cert coverage, and cost-per-kWh — simultaneously.

Pack Architecture

Every layer.
Every tolerance.

Hover each layer to inspect the spec. What looks like a battery pack is actually five precision manufacturing decisions stacked in 187 mm.

187 mm total height
01
Structural Casing
Aluminum 6061-T6 / Stamped Steel
IP67
02
Busbars & Interconnects
Laser-Welded Copper / Aluminum
< 3 ppm
03
Thermal Interface Material
Phase-Change Pad
4.5 W/m·K
04
Prismatic Cell Array
CATL / Samsung SDI / LG ES
280 Ah
05
BMS Board
Firmware-Flashed & Validated
48-pt EOL
Hover a layer
Each layer of the pack has a spec sheet. Hover to inspect the tolerance behind every decision.
Compliance Library

18 certs. Zero
procurement surprises.

Every certification we hold is available as a signed PDF. Procurement leads: download the full cert library before the first conversation.

UN 38.3
Transport Testing
Active
Li-ion cells, modules & packs — air, sea, road
TÜV RheinlandTransport
UL 9540A
Thermal Runaway
Active
BESS fire propagation analysis — utility & C&I
UL SolutionsSafety
IEC 62619
Safety Requirements
Active
Secondary Li cells for industrial applications
SGSSafety
IEC 62660
Cell Performance
Active
Electrochemical performance & reliability
Bureau VeritasPerformance
UL 1973
BESS Standard
Active
Stationary, vehicle auxiliary & light EV applications
UL SolutionsSafety
IEC 62133
Portable Safety
Active
Portable sealed secondary cells & batteries
IntertekSafety
IEC 61960
Performance Test
Active
Secondary Li cells — performance characterization
SGSPerformance
RoHS 3
Hazardous Substances
Active
EU Directive 2015/863 — 10 restricted substances
TÜV SÜDCompliance
REACH
Chemical Safety
Active
SVHC declaration — EU regulation 1907/2006
Bureau VeritasCompliance
9 of 18 certs shown · Full library available on download
Build-vs-Buy Analysis

Request your analysis.
Three fields. No commitment.

Tell us your pack chemistry, annual volume, and email. We'll send a custom build-vs-buy model within one business day — real numbers, your spec.

1
2
3

Not sure? Select "Not yet decided" and we'll recommend a chemistry based on your application profile.

🔒No NDA required
< 24h response
📊Custom model, your spec