Advancing lithium-ion battery (LIB) technologies requires not only the development of innovative materials and chemistries but also effective strategies to scale laboratory research into practical, manufacturable cell formats. In this study, we present the successful prototyping of LIB pouch cells using a fully automated pilot production line. The work emphasizes the optimization of critical parameters necessary to transition high-performance battery systems from laboratory to pre-commercial scale.

Cathode and anode materials were systematically engineered with optimized compositions to enhance electrochemical stability and capacity. Key electrode characteristics - such as mass loading, porosity, and density - were carefully tuned to balance energy density with mechanical integrity during calendering and stacking. Multiple LiFePO₄-based cathode formulations were evaluated, while graphite anodes were refined to achieve high electronic conductivity and low polarization.

Electrolyte formulations were tailored for compatibility with the selected electrode materials, promoting a stable solid electrolyte interphase (SEI) and minimizing gas evolution and degradation during cycling. Various electrolyte volumes and filling techniques were assessed to ensure uniform wetting and to mitigate internal pressure buildup.

The pouch cell design was guided by target energy density requirements, incorporating optimized tab placement, electrode dimensions, separator selection, and packaging parameters. Cell assembly followed a fully integrated sequence on the pilot line, including slurry mixing, coating, drying, calendering, punching, stacking, tab welding, pouch forming, electrolyte filling, and final sealing.

This study underscores the critical importance of integrating materials innovation with scalable cell engineering to bridge the gap between lab-scale development and real-world battery applications. The resulting prototype pouch cells demonstrated consistent and promising performance, representing a significant step toward commercially viable lithium-ion battery technologies.