Our custom lithium-ion prismatic cell pilot line solutions enable you to test and refine electrode recipes, formation cycles, and entire manufacturing processes with the precision needed for confident commercial scaling.
TOBGROUP is committed to bridging the gap between battery technology R&D and mass production by offering a high-precision prismatic cell pilot line. Focused on process scale-up verification, small-batch consistent production, and mass production parameter validation for hard-case cells (aluminum/steel), it comprehensively supports advanced systems including LFP, NCM/NCA, solid-state batteries, and sodium-ion batteries.
The solution adopts a dual-core design of "mass-production genetics + flexible adaptation," ensuring data reliability and process stability while enabling rapid switching between multiple sizes and systems. It provides accurate data support for mass production line construction and reduces industrialization risks.
● Scalable Capacity: 300 - 2,500 cells/day (modular expansion, phased investment)
● Size Compatibility: Thickness 10-80mm, capacity 10-200Ah (supports mainstream specifications such as VDA355/390 and CTP customization)
● Core Systems: LFP, NCM/NCA, solid-state/semi-solid-state, sodium-ion batteries
● Full Process Coverage:
(1) Continuous slurry preparation (including nano-dispersion/dry process)
(2) Double-sided precision coating → high-density rolling (±1μm precision)
(3) High-speed slitting/die-cutting → fully automatic stacking/winding
(4) Shell laser cleaning → electrode assembly insertion and pre-welding → top cover laser sealing (IP67-grade sealing)
(5) Ultra-low dew point electrolyte filling (-45℃ dew point) → formation & shaping → high-precision capacity grading
(6) Full-process MES data traceability + safety inspection (X-ray, leakage test)
TOBGROUP Prismatic Cell Pilot Line Standard Configuration with Full Customization Support
|
Parameter |
Standard Specification/Range |
Customization Options |
|
Standard Output |
800 cells/day |
300 - 2,500 cells/day |
|
Cell Thickness |
20 - 60mm |
10 - 80mm (steel/aluminum shell) |
|
Typical Capacity |
50 - 100Ah |
10 - 200Ah |
|
Shell Size Compatibility |
VDA355 standard |
CTP customization/large cylindrical compatibility |
|
Welding Yield Rate |
≥ 99% (IP67 standard) |
Helium leak rate ≤ 0.01 Pa·m³/s |
|
Environmental Control |
Dry room ≤1% RH, Class 1000 |
Local Class 100, inert gas room |
|
MES Data Trace Points |
300+ |
Expandable to 1,000+ (with AI analysis module) |
|
Delivery Time |
24 - 32 weeks |
18 - 40 weeks (depending on customization) |
Prismatic Cell Pilot Line – Core Validation Platform for Mass Production
● Hybrid Flexible-Rigid Production Line Architecture
(1) Key equipment (laser welders, electrolyte fillers, formation & grading systems) adopts mass production-derived technology to ensure process mechanism consistency
(2) Flexible tooling system supports switching between different shell sizes within 10 minutes (±15% adaptive length/width adjustment)
(3) Reserved interfaces for solid-state battery in-situ curing and dry electrode integration processes
● Enhanced Proprietary Processes for Prismatic Cells
(1) Zero-defect welding: Pulse laser welding + real-time penetration monitoring, hermeticity pass rate >99.5%
(2) Shell cleanliness control: Plasma cleaning + micro-dust control (Class 1000 environment)
(3) Electrolyte filling optimization: Multi-stage vacuum filling + gradient pressure infiltration process, improving electrolyte wetting rate by 30%
● Digital Twin Process Validation
(1) MES system deeply integrated with SPC process control (real-time CPK analysis)
(2) Dynamic warning for key parameters: welding temperature/pressure, filling accuracy (±0.5%), shell deformation (≤0.1mm)
(3) Full lifecycle data package (from slurry to final test) supports one-click export of mass production parameters
● High-Reliability Industrial Design
(1) Key equipment MTBF > 2,000 hours, OEE ≥ 87%
(2) Explosion-proof design meets safety requirements for high-nickel systems (flammable gas monitoring, automatic fire suppression)
● From Process Design to Stable Delivery, TOBGROUP Provides End-to-End Support
|
Phase |
Core Services |
|
In-Depth Needs Analysis |
Diagnosing system characteristics (liquid/solid-state/sodium-ion), target capacity/rate capability/cycle life, shell specifications, safety standards |
|
Customized Line Design |
Integrated solution including cleanroom layout, power configuration (≥300kW), dry room (≤1% RH), inert gas supply |
|
Core Equipment Supply |
Over 20 types of customized equipment, including laser welding stations, high-speed stacking machines, high-vacuum filling machines, pressure formation & shaping cabinets |
|
Smart System Integration |
MES (2,000+ data points collection) + environmental monitoring system + safety interlock device integration and debugging |
|
Process Handover & Training |
Training covers equipment operation, welding process optimization, filling parameter adjustment, safety protocols, and big data analysis tools |
|
Ongoing Upgrade Support |
Mass production line conversion consulting, solid-state battery process package upgrades, remote diagnostic services |
Core enablers of technological implementation
Actionable insights from planning to execution
The hermeticity of prismatic cells relies entirely on laser welding quality. TOB uses a dual-control system with spectral feedback and visual positioning to achieve precise weld depth control of 0.3-0.8mm, avoiding splatter and false welding, thereby providing a reliable sealing process window for mass production.
● An innovative three-stage vacuum gradient filling process is adopted:
① Pre-vacuum shell evacuation to 5Pa → ② Negative pressure filling → ③ Multi-directional pressure infiltration (adjustable pressure 0.5-3MPa)
● Coupled with TOB electrolyte formulation optimization, the infiltration time for 20mm thick electrodes is reduced to 8 hours.
Three core interfaces are reserved:
● Stacking machine equipped with solid-state electrode hot-pressing station.
● Filling station switchable to solid electrolyte film integration module.
● Formation cabinet supports 10MPa pressure loading.
● Upgrade cost is less than 30% of building a new production line.
TOBGROUP delivered a 3000F 60138 supercapacitor pilot line with full equipment, materials, and on-site commissioning support.
TOBGROUP designed a Na-ion battery lab line producing 18650S, 32138S, 32140S cells for advanced research and development.
TOBGROUP delivered a full-cycle 5MWh pouch cell production line for Li-ion and Na-ion, enabling European energy storage production.
