Precision
Manufacturing at Scale

Advanced factory for high-performance, wide-temperature lithium-ion cells with automation, quality, and sustainability.

Years Battery Expertise

Automated Production Lines

International Certifications

Inspection Steps Ensured Quality

Engineers Driving Innovation

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Transparency in Lithium-Ion Battery Manufacturing

At Ultraxel, we believe transparency is the foundation of trust. By openly sharing our fully automated lithium-ion battery manufacturing process, we ensure every cell undergoes rigorous quality control to meet the highest standards of safety, reliability, and performance. This commitment empowers industries worldwide with traceable, consistent, and dependable energy storage solutions.

Slurry mixing process (lithium battery)

Electrode powders are precisely mixed with solvents in controlled environments to create a homogeneous slurry. Achieving uniform slurry consistency is critical for ensuring consistent coating quality and optimal electrochemical properties of lithium-ion battery electrodes.

Electrode coating drying process

The prepared electrode slurry is evenly coated onto metal current collectors, typically aluminum foil for cathodes and copper foil for anodes. The coated foils then undergo a drying process to remove solvents, resulting in solid electrode plates with uniform thickness and structure.

Electrode Slitting

After drying, electrode plates are slit into narrow strips with precise widths to match cell design specifications. Accurate slitting is essential for ensuring efficient cell assembly and maintaining electrode integrity.

Electrode & Separator Winding

The positive and negative electrode strips are tightly wound together with a separator and tabs to form the bare cell core. This winding process determines the cell’s capacity and structural stability.

Battery Cell Assembly

The bare cell core is carefully inserted into protective steel cans or other housings. Additional components such as insulating gaskets and safety valves are assembled to ensure mechanical protection, electrical insulation, and safe operation.

Electrolyte Injection Battery

High-purity electrolyte solution is injected into the assembled cell under controlled conditions. The cell is then hermetically sealed to prevent contamination and electrolyte leakage, creating an unactivated lithium-ion cell ready for formation.

Battery Formation

Cells undergo their first controlled charge-discharge cycles, known as formation. This process activates the internal chemical reactions, including the formation of a stable solid electrolyte interphase (SEI) layer on the electrodes, which is vital for battery longevity and performance.

Battery Formation Aging

Following formation, cells are aged under specified high-temperature and room-temperature environments. Aging allows cells to stabilize electrochemically, helps identify early failures, and ensures consistent long-term reliability.

Battery Cell Grouping

Finally, cells are sorted into groups based on key electrical parameters such as capacity, voltage, and internal resistance. Grouping ensures that cells assembled into battery packs have matched characteristics, optimizing overall pack performance and lifespan.

FAQ

How to improve the uniformity of electrode slurry?

To boost electrode slurry uniformity: Optimize viscosity, ensure strong shearing during mixing (use high-shear mixers), add materials stepwise (binder solution first, then conductive agent, lastly active material slowly), and degas under vacuum. Control temperature and mixing time precisely.

How to avoid bubbles during the slurry mixing process?

To avoid bubbles in slurry mixing:

Mix slowly to minimize air entrainment.

Avoid vortex formation (use baffled tanks).

Use defoamers if compatible.

Degas under vacuum if critical.

How to ensure uniform electrode coating?

To ensure uniform electrode coating:

Control slurry viscosity

Optimize coating speed

Maintain precise gap/doctor blade

Ensure consistent drying

Use homogeneous slurry mixing

How to Slit Lithium Battery Electrodes？

To slit lithium battery electrodes:

Use precision slitting machinery

Maintain optimal tension to prevent wrinkles

Wear proper PPE (gloves, goggles)

Ensure blades are sharp and contamination-free

Control environment to avoid metal dust

Monitor slit width tolerance (±0.1mm)

Inspect edges for burrs & defects post-slit

How Electrolyte Injection Creates an Unactivated Battery Cell？

Electrolyte injection fills the dry cell (anode, cathode, separator), enabling future ion flow. However, the cell remains unactivated until the first charge (“formation”) creates protective electrode interfaces (SEI).

How does aging stabilize battery cells?

Aging stabilizes batteries by forming a stable Solid-Electrolyte Interphase (SEI) layer. This protective barrier reduces harmful side reactions between the electrode and electrolyte. However, it also consumes active lithium, lowering capacity.

Why Our Manufacturing Process Matters

Every step in our lithium-ion battery production is designed to optimize quality and performance. Through advanced automation, strict environmental controls, and rigorous testing, we deliver batteries that power applications from consumer electronics to electric vehicles with safety and reliability you can trust.