My Experiences
A look at what I have worked on and learned at each company: real processes, real problems and real fixes. Click any topic below to read the full write-up.
ATL Li-ion pouch cell manufacturing: process flow & defects ▶
A pouch cell goes through about 15 stages, from mixing the electrode slurry to final inspection and dispatch. The write-ups below follow that order, and each one explains what the step does, what is controlled and what typically goes wrong. The second list groups the defects seen across the line.
Li-ion Battery Manufacturing Process
The full process flow, step by step, from slurry mixing to dispatch.
- •Overview: The Life Cycle of a CellHow a pouch cell travels from raw materials to a shipped product, and where each quality check sits.›
- 1Slurry MixingActive material, conductive carbon, binder and solvent are mixed into a uniform slurry. Viscosity and solid content decide how well it coats.›
- 2Electrode CoatingThe slurry is coated on copper foil (anode) or aluminium foil (cathode) at a controlled thickness and coating weight.›
- 3Electrode DryingSolvent is driven out in oven zones. The temperature and speed profile affects adhesion and cracking.›
- 4Electrode CalenderingRolls compress the dried electrode to the target thickness and density.›
- 5Electrode SlittingThe wide roll is cut into strips of the cell width. Burrs and edge quality matter for safety.›
- 6Winding / StackingAnode, separator and cathode are assembled into a jelly roll or a stack with alignment control.›
- 7Auto PackingThe jelly roll with its tabs is placed in the formed laminate pocket and the edges are sealed.›
- 8Vacuum Baking & Electrolyte InjectionMoisture is baked out under vacuum, then the electrolyte is filled in a dry room.›
- 9Activation (ACT / Formation)The first charge forms the protective layer on the anode and sets the cell up for stable cycling.›
- 10DegassingGas produced during formation is removed and the cell is resealed.›
- 11FEF (First Edge Folding)The sealed edges are folded to bring the cell to its final dimensions.›
- 12OCV TestingOpen circuit voltage is measured after rest to find cells with self-discharge or a micro short.›
- 13X-Ray InspectionLooks inside the sealed cell for electrode alignment and internal defects.›
- 14FQI (Final Quality Inspection)Final visual, dimensional and electrical checks before the cell is accepted.›
- 15Final Inspection & DispatchLast check, packing and release of the cells to the customer.›
Li-ion Battery Defects
Common defects seen across the line, grouped by area.
- 1Common Laminate & Pocket DefectsProblems in the aluminium laminate film and the formed pocket.›
- 2Jelly Roll (JR) Handling DefectsDamage and misalignment while the jelly roll is moved and loaded.›
- 3Tab Related DefectsTab welding, bending and position problems.›
- 4Cutting & Folding DefectsFaults from the cutting and folding steps.›
- 5Cutting & Finishing DefectsEdge and finishing issues after cutting.›
- 6Sealing DefectsWeak or incomplete seals that can cause leakage.›
- 7Dimension & CCD Inspection DefectsOut-of-tolerance size and camera inspection rejects.›
- 8Barcode & Printing DefectsUnreadable or wrongly printed labels and codes.›
- 9Electrical DefectsVoltage, resistance and capacity failures found in testing.›
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