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Battery Manufacturing & Testing

Delivering over 110 electric vehicle (EV) battery manufacturing and test lines has taught us a few things.

Our proven automation and testing solutions for EV and battery energy storage systems (BESS) module and pack assembly help OEMs quickly shift to full-scale production lines to meet current and future customer demands. With over 20 years of experience designing and building automated systems for battery manufacturing and testing, ATS Industrial Automation experts are now helping the energy industry design and scale batteries with a modular and flexible solution.

Customer Challenges

Ramping up battery production efficiently and cost-effectively to meet market growth.

Finding a global partner with expertise in moving from pilot to full-scale battery assembly and testing. 

Supporting multiple product platforms and battery configurations. 

Identifying relevant tests for each stage of the battery manufacturing process. 

Every EV battery project is unique. Allow us to listen to your challenges and share how automation can launch your project on time.

Customer Benefits

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Meet Market Demand

End-to-end battery assembly and testing solutions help OEMs shorten their lead time to manufacture commercial products.

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Production Efficiency

Manufacturing teams can use digital simulation to streamline processes before the physical build. 

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Scale

Drive high-throughput using consistent automated battery manufacturing.

Automated battery assembly system, showcasing yellow robots with a vision system to pick up parts.

Battery Module

We work with automotive and battery OEMs to create an automated assembly and testing process for high-throughput EV battery module production. Our solutions automate cell handling, sorting, and assembly, while our precision welding ensures module integrity. In-process testing validates each step of the assembly process, ensuring only verified cells and modules make it into pack assembly. 

Battery Pack

Our modular solution supports a range of EV configurations, helping customers scale production with consistent and replicable assembly automation. Our comprehensive testing, including end-of-line testing, validates each final pack and establishes traceability. What’s more, we work with customers to train their workers on using and maintaining the new technology, helping teams ramp up and sustain lines with confidence. 

EV Battery Pack Assembly
End of line testing system for an EV battery assembly system.

Battery Assembly Testing

Manufacturing EVs and energy storage batteries demands a high level of precision. It’s essential to employ rigorous testing at every stage—from individual cells to fully assembled modules and packs—to ensure the final product’s quality, performance, and safety. We collaborate with customers to develop automated test systems that optimize efficiency and success in battery production.

Our testing systems also help validate, debug, and identify design or assembly issues early in the process, preventing costly delays. From manually loaded stations to fully automated high-speed equipment, our systems and software can adapt and scale with the assembly line as the manufacturing business grows. 

Battery Manufacturing & Testing Solutions For

Cylindrical Battery Cells

Cylindrical Cells

The assembly of batteries using cylindrical cells requires meticulous handling to ensure high-quality and reliable modules. Cylindrical cells demand precise welding, careful material handling, and thermal management. Cylindrical cells also have dimensional variability. An automated assembly line, buffer system, and rigorous cell testing can address these challenges in cylindrical battery production. 

Pouch Cells

Pouch Cells

While pouch cells are efficient, they’re also fragile, making them more susceptible to damage. Enclosed in a flexible foil, they require careful handling during production. Vacuum handling can help manufacturing teams avoid distorting the foil seam or stressing the tabs. OEMs can also utilize incoming cell validation, precision welding, and comprehensive testing to ensure pouch cells’ reliability and safety. 

Prismatic Cells

Prismatic Cells

Prismatic battery assembly and testing involve several critical steps to ensure durability and efficient space utilization. Characterized by their flat, rectangular shape and rigid casing, these cells are ideal for high-demand applications such as EVs and grid storage systems. Validation tests, electric array formation and in-line and end-of-line testing play a crucial role to ensure the cells’ performance. 

“ATS Industrial Automation is critical in enabling us for battery assembly and exponential volume.”

VP of Global Manufacturing & Engineering,

Large North American Automotive OEM