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Custom Dry Pouch Cell Fabrication Service for R&D

Custom Dry Pouch Cell Fabrication Service for R&D

Atomfair provides precision, research-grade custom dry pouch cell (unfilled cell) prototyping services for university researchers, national laboratories, and industrial battery R&D centers. These precision dry cell stacks are fully assembled, tab-welded, and pouch-sealed with an extended open gas-bag, ready for direct inert-atmosphere electrolyte filling, wetting dynamics evaluation, and electrochemical screening in gloveboxes.

Our platform accommodates both Full-Turnkey (standard Atomfair baseline electrodes, pure/composite alkali metal foils, and separators) and Customer-Supplied Component builds (integrating client proprietary coated electrodes or specialized solid-state/composite membranes) across multi-chemistry architectures. Mutual NDAs are available upon request whenever proprietary formulations or custom drawings require formal protection.

1. Engineering Specifications & Assembly Capabilities

Assembly Parameter Specification & Customization Scope
Electrode Stacking Architecture Single-Layer (Monolayer) Pouch Cells: 1 cathode / 1 anode pair with double-sided separator envelope. Optimized for operando optical diagnostics, in-situ gas monitoring, and small-volume novel electrolyte qualification.
Multi-Layer Stacks (Z-Fold Stacking): 5 to 35+ double-sided active layers engineered for high-energy prototype validation (0.1 Ah to 5.0 Ah scale).
Pouch Geometries & Formats Standard Established Tooling: 46 × 65 mm, 47 × 78 mm, 60 × 90 mm, 75 × 120 mm, 88 × 124 mm, and bespoke deep-drawn cavity dimensions.
Sealing Features: Precision 3-side hermetic seal with integrated extended gas-bag for secondary vacuum degassing and resealing.
Alkali Metal & Anode-Free Handling Dedicated inert-atmosphere dry room/glovebox assembly for pure Li/Na foils, roll-to-roll mechanical cladding (Li-Cu, composite Na), and bare/nucleation-treated Cu foil current collectors for anode-free configurations.
Tab Specifications & Welding Precision ultrasonic tab welding. Tab materials: Nickel-plated copper, pure aluminum, and pure nickel tabs. Polarity orientation customizable: same-side (top exit) or opposite-side (top/bottom exit).
Separator Integration Compatible with polyolefin (PP/PE/Celgard), ceramic-coated (Al₂O₃/Boehmite), non-woven cellulose, glass fiber, and customer-supplied functional polymer/solid-state composite membranes.
N/P Balancing Ratio Precise areal capacity balancing (typically 1.05 – 1.20 for graphite/hard carbon anodes, controlled low-excess N/P for metal foils, or zero-excess N/P = 0 for anode-free systems). Tolerance: ≤ ±2.0%.
Minimum Order Quantity (MOQ) Flexible pilot batch sizes: small proof-of-concept screening (5 – 10 cells) up to evaluation batches (20 – 100+ identical dry cells).

2. Multi-Chemistry Battery Platforms Supported

Lithium Metal Systems

• Pure Lithium Metal Foil: Free-standing ultra-thin Li foils (20–100 μm) for baseline metal testing
• Lithium-Copper (Li-Cu) Composite Anodes: Single- or double-sided mechanically cladded Li on Cu foil substrates for enhanced mechanical integrity
• Anode-Free Lithium Metal (AFLMB): Zero-excess bare or interfacial-coated Cu foil for high energy density nucleation and CE evaluation

Sodium Metal Systems

• High-Purity Sodium Foil: Custom-rolled pure Na strips for full-cell benchmarking and plating kinetics
• Composite Sodium Anodes: Carbon/metal framework supported sodium composites for dendritic suppression
• Anode-Free Sodium Metal (AFSMB): Current collector substrates (Cu/Al/carbon-coated) for zero-excess Na plating/stripping characterization

Intercalation Li-Ion & SIB

• Lithium-Ion: High-Nickel NCM811/Ni90, Single-Crystal LCO (up to 4.5V), LFP/LMFP vs. Graphite or Si-C
• Sodium-Ion: Layered Oxides (O3/P2), NFPP, NVP, and Prussian Blue Analogs (PBA) vs. Hard Carbon
• High-Rate Platforms: Spinel LNMO & Lithium Titanate (LTO)

Lithium-Sulfur & Emerging

• Lithium-Sulfur: High-loading Sulfur-Carbon cathodes paired with cladded Li-Cu or protected Li anodes
• Aqueous/Non-Aqueous Zinc-Ion: MnO₂, V₂O₅ cathodes paired with pure Zn foil anodes
• Solid-State Composites: Semi-solid gel polymer & sulfide/oxide composite dry cell stacks

3. Custom Dry Cell Fabrication Workflow

PHASE 1: CELL DESIGN
N/P ratio capacity balancing, active layer count calculation, pouch dimensional freeze, and optional NDA execution if required.
PHASE 2: PREPARATION
Precision laser or die slitting of cathode/anode sheets, metal cladding/slitting in dry room, tab strip clearance cutting, and separator alignment.
PHASE 3: STACK & WELD
Semi-automated Z-fold stacking, ultrasonic metal tab welding, pouch cup thermoforming, and three-side edge heat-sealing.
PHASE 4: VACUUM DRY & PACK
Multi-stage vacuum oven baking, Karl Fischer moisture sampling, and hermetic inert-gas barrier bagging with desiccants.

4. Quality Control & CoA Delivery Standards

Because unfilled dry pouch cells serve as precise baselines for electrolyte testing, each batch is shipped with an engineering Certificate of Analysis (CoA) strictly verifying:

1. Actual Electrode Mass & Areal Capacity

Measured active mass distribution and nominal capacity rating based on tare-deducted punch sampling, verifying exact N/P capacity balance for electrochemical stability.

2. Karl Fischer Moisture Titration

Coulometric Karl Fischer titration verifying post-bake dryness (residual moisture verified < 150–200 ppm) to ensure moisture-sensitive electrolytes will not hydrolyze upon filling.

Confidentiality & Institutional Procurement Support
  • Confidentiality on Demand: Mutual Non-Disclosure Agreements (NDAs) can be executed promptly upon request whenever proprietary formulations, custom drawings, or non-standard architectures require formal legal protection.
  • Academic & Corporate Procurement: Official university Purchase Orders (POs), Net-30 payment terms, formal PDF quotations, and institutional vendor onboarding packets are fully supported.
  • Immediate Glovebox Transfer: Every dry pouch cell order is hermetically sealed in multi-layer aluminum barrier pouches under dry inert atmosphere (Argon/Nitrogen) for seamless glovebox introduction.

5. Frequently Asked Engineering Questions (FAQ)

Q: Are the dry pouch cells ready for immediate electrolyte injection?

Yes. Cells are delivered completely dried, stacked, and three-side edge sealed with an extended open gas-bag. You only need to transfer them into an inert glovebox, inject electrolyte, and conduct final vacuum heat-sealing.

Q: Can you fabricate Anode-Free and thin alkali metal cells?

Yes. We support pure lithium foil, roll-to-roll mechanically cladded Li-Cu composite anodes, pure/composite sodium anodes, as well as zero-excess Anode-Free (bare Cu foil) configurations assembled under strict inert conditions.

Q: What tooling formats are readily available for rapid sampling?

Standard tooling is maintained for 46 × 65 mm, 47 × 78 mm, 60 × 90 mm, 75 × 120 mm, and 88 × 124 mm cavities. Custom punch dies and deep-drawn tooling can also be machined for non-standard project geometries.

Q: Can we supply our own specialized coated electrodes or solid-state separators?

Yes. Under our consignment fabrication service, clients can send custom-coated electrode rolls or functional membranes. We can execute a bilateral NDA upon request and handle precision slitting and stacking per your specification.

Start Your Custom Project (RFP / Inquiry Template)

Copy the specification matrix below, fill in your experimental parameters, and send it directly to our engineering desk at inquiry@atomfair.com:

1. Battery Chemistry Platform: [Li-ion / Na-ion / Pure Li-Metal / Li-Cu Composite / Anode-Free Li / Pure Na-Metal / Composite Na / Anode-Free Na / Li-S / Zn-ion] 2. Electrode Sourcing: [Turnkey Standard Baseline OR Customer-Supplied Coated Electrodes] 3. Cell Architecture: [Single-Layer Pouch Cell (1 cathode/1 anode) OR Multi-Layer Stacking (Specify Layer Count / Target Ah)] 4. Target Pouch Dimensions: [Standard Tooling: 46×65 mm / 47×78 mm / 60×90 mm / 75×120 mm / 88×124 mm, OR Custom L×W mm] 5. Tab Configuration: [Same-Side Top Exit / Opposite-Side Exit; Ni-plated Cu / Al / Pure Ni] 6. Separator Type: [Standard PP/PE Celgard / Ceramic-Coated / Glass Fiber / Customer-Supplied Membrane] 7. Target N/P Balancing Ratio: [e.g., 1.10 – 1.15 (Graphite/HC), Controlled Low-Excess Metal, or Lean Anode-Free (N/P = 0)] 8. Target Order Volume: [e.g., 10 / 20 / 50 / 100 cells] 9. Downstream Services: [Dry Pouch Delivery Only / Electrolyte Injection Service / Formation & Cycling Testing] 10. Confidentiality Requirements: [Standard Processing / Mutual NDA Required Prior to Disclosure]

Related Battery Research Resources

Research Objective Atomfair Platform Resource Integration Context
Standard Off-the-Shelf Dry Cells Dry Pouch Cells Category Pre-built standard baseline cells (NCM811, LCO, LFP) ready for immediate electrolyte qualification.
Custom Electrode Coating Electrode Coating Service Guide Precision slot-die and dry PTFE electrode coating service for proprietary cathode/anode formulation.
Ready-to-Use Electrolytes Battery Electrolytes & Additives High-voltage, low-temperature, and functional ester/ether electrolyte formulations for cell injection.
Comprehensive Research Guide Battery Research & Materials Guide End-to-end technical guide linking materials, cell assembly fixtures, and electrochemical diagnostics.

Discuss Your Custom Dry Cell Project

To initiate an engineering feasibility review, send your target chemistry, layer architecture, dimensional requirements, and quantity to our engineering desk. Formal PDF quotes, university Purchase Orders (POs), and mutual NDA execution (if required) are handled promptly.

Direct Engineering & RFQ Inquiries: inquiry@atomfair.com

Note: Custom dry cells are evaluated for research-scale prototyping feasibility. Final quotation, tooling availability, and delivery lead times depend on confirmed cell dimensions and material parameters.