Re:Build Optimation

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Scalable Battery Production and Assembly System

Turnkey robotic automation and material handling for high-throughput battery manufacturing

Capabilities Demonstrated

  • Turnkey automation and robotic integration
  • Custom material handling design and fabrication
  • Control system programming and safety integration
  • Mechanical engineering and precision assembly
  • Global system sourcing and integration
  • Onsite installation and alignment

The Challenge

A U.S.-based battery manufacturer needed to dramatically increase production capacity to meet growing demand in defense, medical, industrial communication, and emerging consumer markets like wireless security and home automation. The client sought a high-throughput, fully automated production line that could operate 24/7 with precision, safety, and scalability.

To capture near-term market share and justify a major capital investment, the system needed to support current production needs while offering a clear path to triple capacity with minimal additional investment. Integration of legacy systems with advanced robotics and globally sourced subsystems was essential to meet both timeline and performance expectations.

Approach

Re:Build Optimation served as the turnkey integration partner, delivering a complete automation solution from concept through commissioning. The team led all phases of the project, including:

  • Designing, fabricating, and installing custom conveyance and material handling systems
  • Integrating new and existing production equipment across multiple work centers
  • Installing and programming four SCARA 4-axis robots with custom end-of-arm tooling
  • Engineering all guarding, cages, and mechanical supports
  • Implementing Rockwell ControlLogix for unified safety and automation control
  • Sourcing and integrating components from the U.S., Canada, and China
  • Managing system relocation, on-site reassembly, and micron-level alignment

Solution

Re:Build Optimation delivered a fully integrated robotic assembly line tailored to lithium battery products. The system combined high-speed robotic work cells with custom conveyors, precision fixturing, and automated safety systems to ensure accurate and repeatable performance.

Each SCARA robot was paired with pneumatic grippers, sliders, and rotators to handle sensitive components with sub-millimeter precision. The Rockwell ControlLogix platform provided centralized communication and control across all stations. The modular architecture allows for straightforward scaling to support future production increases.

Results

The system is now entering the startup phase, with production expected to ramp quickly. This initiative marks the client’s largest capital investment in over a decade and is projected to significantly boost output, quality, and profitability. As forecasted demand materializes, the scalable design will allow the manufacturer to triple throughput without extensive upgrades, solidifying their competitive position in the growing lithium battery market.

System Overview

  • System Type: Automated lithium battery assembly line
  • Function: High-volume production of lithium power sources
  • Key Features: SCARA robots, custom end-of-arm tooling, precision-aligned conveyors, Rockwell ControlLogix automation
  • Deployment:S.-based manufacturing facility with globally sourced components
  • Industries Served: Energy storage, defense, industrial communications, consumer electronics

Benefits & Impact

  • Enabled continuous, high-throughput battery assembly with minimal manual input
  • Improved quality and repeatability with robotic precision to 0.001 mm
  • Reduced labor costs while enhancing operator safety
  • Unified legacy and new systems through a single control platform
  • Positioned for scalable production growth in key domestic and international markets
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