Tab and busbar welding
Acoustic emission and vision for ultrasonic and laser welds whose quality is invisible afterwards.
Industry
Battery cell, module and pack
Inline quality for cell, module and pack lines: in Europe now, in India as the cell plants come online.
The situation
What plants in this sector tell us
- Scrap in the first ramp years measured in double-digit percentages, and each point worth millions a year.
- Weld quality that is invisible once the module is closed.
- Recipes and chemistry that cannot go anywhere near a vendor cloud.
- Defect causes discovered at end-of-line testing, several stations too late to act on.
Yield decides the economics of a gigafactory, and many defect-creating steps are fast, sealed or both. Our experience with German battery cell and module manufacturers maps onto Europe's cell plants today, onto India's cell, module and pack lines as the cell plants come online from 2027: multi-modal sensing station by station, edge inference at the line, and sovereign deployment because cell chemistry and recipes are trade secrets. Solvent and electrolyte areas are explosion-protected zones and need certified hardware.
Where we help
Where our methods apply
Module and pack assembly
Fastening, thermal-interface and connector-seating signatures correlated with end-of-line results.
EvidenceProject experience with German battery cell and module manufacturers; weld-monitoring research led by our founder (Crystals 2023, DOI 10.3390/cryst13101451; Applied Sciences 2023, DOI 10.3390/app131810548). Context: Fraunhofer FFB and RWTH PEM report scrap rates of 15 to 30 percent in the first years of cell production, and about EUR 10 million a year per percentage point of scrap for a 40 GWh plant (whitepaper, 2024).
By asset
The machines we listen to in this sector
Welding cells
Laser and arc welds monitored in-process by airborne acoustic emission; the same pattern is proposed for resistance and ultrasonic welding.
How we would start
The services this sector uses most
Almost every engagement begins with a feasibility study or a discovery call, because the cheapest thing to establish first is whether the signature is there at all.
Multi-modal sensing + edge AIRuggedised sensor units and on-device AI.Open service page Co-development R&D and PoCApplied R&D on your process, with your engineers.Open service page Industrial dataset creationCampaigns, labels, QA and versioning you own.Open service page Sovereign AI & federated learningOn-premise AI and federated learning across plants.Open service page
Start here
Discuss a project in Battery cell, module & pack
Tell us the asset or the station, what goes wrong and how often. We answer every enquiry within 48 hours on working days.
- Your data stays on site; on-premise and on-device deployment is the default
- We work alongside the monitoring system you already run
- Honest go / no-go before any large spend
Ready to find out if it works on your machines?
Start with a free 30 to 45 minute discovery call. Bring the problem, the recordings you already have and your questions. We will tell you honestly whether sensing-based AI is the right tool and what the next step would cost in days, not months.