Automated Robotic System for Solid Oxide Fuel Cell Stacking

Compact high-precision system for 10x production scale-up

Capabilities Demonstrated

Custom robotic machine design
Precision system integration
Laser enclosure design and certification
Automated welding and vision inspection
Process design for throughput optimization

The Challenge

A manufacturer in the energy sector set out to transform one of its facilities from a research and development site into a scaled production environment for Solid Oxide Fuel Cells (SOFCs). To support this transition, the company needed to replace a limited in-house system with a fully automated, high-throughput machine capable of assembling SOFC stacks with speed and precision.

The project called for tight dimensional tolerances of ±0.5 mm, a compact 64″ x 64″ footprint, and a production target of one completed stack every 53 minutes. Multiple processes—including stacking, welding, vision inspection, and laser marking—had to be integrated into one seamless, ergonomic system.

Approach

Re:Build Optimation served as the turnkey automation partner for the project, delivering a complete design, build, and integration solution. Key elements of the approach included:

Designing a dual-station build layout around an EPSON SCARA robot with servo-driven slides
Integrating a vision inspection system to identify part centers and tab orientations for accurate alignment
Developing a welded steel tower and surrounding 8020 frame for structural precision
Installing safety light curtains to allow parallel operation between build and load stations
Incorporating a spot welding station for stainless steel interconnect tabs
Designing and certifying a custom Class 1 laser marking enclosure with ergonomic part drawer

Throughout the engagement, Re:Build Optimation collaborated closely with the client’s operators and engineers, including two on-site validation visits to ensure familiarity and confidence with the system prior to shipment.

Solution

The final system featured a centrally located EPSON SCARA robot flanked by two opposing build stations, enabling continuous operation. As one stack was being built, the other station could be safely accessed and reloaded with parts, thanks to integrated light curtains.
A servo-driven slide handled precise part stacking, while a vision system enabled real-time part alignment within the required ±0.5 mm tolerance. Additional stations included:

A spot welding unit for connecting Nichrome wire to tabbed interconnects
A laser scribing station for part identification, built around a Videojet laser and certified Class 1 enclosure
Barcode scanning, interior lighting, and 3-sided access for enhanced usability and maintenance

The entire system was designed for compactness, robustness, and throughput, packing all features into a 64″ x 64″ footprint.

Results

Re:Build Optimation delivered a fully automated fuel cell stacking sys-tem that exceeded production benchmarks and positioned the client for rapid scale-up. With enhanced speed, precision, and ease of use, the system replaces a legacy in-house setup and reflects the client’s largest automation investment to date. The success of this project deepened the partnership and created a strong foundation for future collabora-tion.

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

Increased Throughput: Achieved a 50-minute build cycle, exceeding the 53-minute requirement by 6%
Precision Alignment: Maintained stack concentricity and orientation within ±0.5 mm
Compact Footprint: All systems fit within a 64″ x 64″ layout
Operator-Friendly: Interior lighting and ergonomic access improved usability
Customer Confidence: Hands-on validation with client’s operators ensured seamless adoption

Ready to Partner?

Let’s talk about your unique challenges and how Re:Build Optimation can help you.