High-Performance Battery Solutions for Advanced Manufacturing

Scalable Lithium Battery Production and Assembly System

Capabilities Demonstrated

Automated Materials Handling & Assembly – Full system integration of robotics and custom workstations.
Advanced Robotics & Controls – SCARA 4-axis robotic automation with real-time process control.
Precision Engineering & System Alignment – Conveyor and robotic positioning with .001 mm accuracy.
Turnkey Installation & System Integration – From Factory Acceptance Testing (FAT) to site reassembly and commissioning.
Scalable Manufacturing Infrastructure – Designed for immediate high-volume production with the ability to triple throughput as demand grows.

The Challenge

A battery manufacturer wanted to increase productivity and total product throughput on a 24-hour cycle using robot technology and other automated peripheral devices.

Re:Build Optimation was approached by a global manufacturer of specialty battery power sources, renowned primarily in defense, medical, safety, and industrial radio advanced RF communications markets. The client aimed to seize an opportunity to gain market share, revenue, and greater profitability through the introduction of advanced automated assembly capabilities. Prospective new market opportunities in wireless security and home automation meant a potentially near-immediate and explosive opportunity lay before them, if they acted quickly and effectively.

The system was to be built for their lithium products line and tailored to these market needs for optimal results. After surveying commercially available subsystems for production, the client settled on a variety of custom-designed stations to be integrated by Re:Build Optimation. The operation would be based in the company’s American manufacturing center.

Re:Build Optimation and the client specified and coordinated a backbone of custom material handling. It tied together various work-centers of existing client equipment and new custom systems. Re:Build Optimation devised an architecture that met the initial production capacity targets and could expand to deliver more than triple that amount with only small capital upgrades required as demand grew.

Solution

Re:Build Optimation designed, fabricated, and installed a fully automated materials handling and production system, integrating both custom equipment and third-party components into a cohesive, high-efficiency workflow.

Key System Features & Technologies

Integrated SCARA 4-Axis Robots – Automated material handling and production flow mitigation with full safety protocols.
Allen-Bradley ControlLogix Platform – Provided seamless control and communication across all automated systems.
Custom Robotic Workstations – Designed end-of-arm tooling, including pneumatic grippers, rotators, and sliders to optimize assembly.
Precision Alignment for Automated Conveyors – Ensured repeatability and accuracy down to .001 millimeters, critical for robotic efficiency.
Turnkey Installation & System Integration – Re:Build Optimation handled Factory Acceptance Testing (FAT), site relocation, reassembly, and precision installation.

Results

Re:Build Optimation’s advanced system architecture and robust automation enabled production volumes previously unattainable through manual assembly, positioning the manufacturer for long-term scalability and cost efficiency.

Key Outcomes

Scalable Production Capacity – Designed for immediate high-volume output with the ability to triple throughput as demand grows.
Global Equipment Sourcing & Seamless Integration – Leveraged components from USA, Canada, and China, unified through a Rockwell-based control system.
Cost-Effective Domestic Manufacturing – Enabled high-volume lithium battery production in the USA, eliminating reliance on outsourced assembly.
Maximum Safety & Quality Standards – Delivered consistent, high-quality lithium battery assemblies with minimal manual interaction.

With this state-of-the-art automated production system, the client expects to achieve record-breaking throughput, justifying its largest capital investment in the past decade while securing a competitive edge in the fast-growing lithium battery market.

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Let’s discuss how we can bring innovative solutions to your most challenging projects. Contact Re:Build Battery Solutions to learn more about our expertise in Battery Pack Design and Development for advanced applications.