WUXI, China, Nov. 21, 2025 – With the global energy transition accelerating, solid-state batteries are emerging as a leading next-generation energy storage technology. While offering exceptional safety and energy density, they face significant mass production challenges, particularly in the stacking process.
To overcome this hurdle, LEAD has introduced a stacking machine specifically engineered for solid-solid interface characteristics, thereby establishing new benchmarks for advanced battery manufacturing.
Technical Challenges in Solid-State Battery Manufacturing
All-solid-state batteries fundamentally replace the liquid electrolyte and separator found in conventional lithium-ion cells with solid electrolytes, such as oxides, sulfides, and halides. Despite their varied properties, these materials share a common difficulty: creating a stable, low-impedance “solid-solid” interface crucial for efficient lithium-ion transport.
Under these exacting conditions, precise battery cell stacking is paramount for building high-performance cells. It ensures accurate layer alignment, uniform pre-stress application, and enhanced compatibility with delicate materials.
However, achieving this level of stacking precision encounters several technical obstacles:
- Solid electrolytes are extremely sensitive to moisture and air, demanding ultra-dry, sealed environments to prevent degradation or the formation of toxic gases.
- The brittle nature of these materials requires specialized pressing and cutting processes during high-speed transfer and stacking.
- Maintaining consistent interlayer pressure and ultra-high precision alignment is vital to eliminate voids and avert short circuits—issues that traditional equipment often struggles to address.
At this juncture, stacking represents the most reliable and cost-efficient method for scalable, high-performance solid-state cell manufacturing.
LEAD’s Comprehensive Stacking Optimization Solution
To overcome these critical challenges, LEAD has independently developed a new generation of integrated solid-state battery cutting and stacking machine.
Ultra-High-Precision Processing
- Achieves ±0.15 mm alignment accuracy through high-speed vision-based positioning and platform correction.
- Dual-loop pressure/displacement control ensures tight, uniform contact while preventing indentation and micro-damage.
- A biomimetic suction design guarantees zero-damage, high-speed handling of fragile sheets.
Mass-Production Efficiency
- Integrated framing-cutting-stacking eliminates transfer time between machines, achieving an efficiency greater than 0.35 seconds per piece.
- Modular architecture supports rapid changeovers for various sizes (100–700 mm × 80–150 mm × 1–30 mm), compatible with a wide array of solid-state battery designs.
Intelligent Closed-Loop Control
- Built-in monitoring for dust, hazardous gases, and dew point allows for microsecond-level contamination alerts.
- Vision defect inspection, combined with a PHM (Prognostics and Health Management) predictive maintenance system, ensures real-time quality assurance.
- Ergonomic human-machine design enhances Overall Equipment Effectiveness (OEE) and reduces operating costs.
Through profound innovation in cutting and stacking technologies, LEAD has developed an end-to-end solid-state battery solution that integrates insulation frame preparation, precision framing, notching & cutting, and high-speed stacking. Supported by proprietary precision machining and intelligent production systems, LEAD’s solid-state solution establishes new manufacturing standards and positions the company at the forefront of next-generation solid-state battery production.
Media Contacts
Website: https://www.leadintelligent.com/en/
Email: pr@leadintelligent.com
