The scalability and energy efficiency of battery production are among today’s most crucial challenges to support the growth of electric mobility and energy storage systems (ESS). To meet these needs, Comau and Intecells have developed an innovative industrial solution based on cold plasma for cell surface treatment.
A step forward in roll-to-roll processes
The technology integrates Intecells’ expertise in atmospheric plasma with Comau’s large-scale industrialization and automation capabilities. Applied directly to the surface of electrodes and separators in roll-to-roll processes, cold plasma optimizes material wettability.
Operational and performance benefits for cell manufacturers include:
Reduced cycle times
Higher wettability accelerates critical stages of electrolyte filling, soaking, and drying
Smaller footprint
The process reduces the heat required compared to traditional methods, lowering energy consumption, plant footprint, and capital expenditure (Capex)
Optimized performance
Uniform soaking helps decrease the cell’s internal resistance, improving overall performance
From research to gigafactory: end-to-end flexibility
The integration of cold plasma fits into a broader vision of flexible automation for the entire battery value chain.
A practical example of this modularity is the recent semi-automatic cell formation and testing hub developed for the National Institute of Chemistry (NIC): a versatile platform capable of handling pouch, cylindrical, and prismatic formats, supporting processes from laboratory prototyping to high-power testing for automotive and industrial applications.
This combined approach—bringing together materials process innovation and scalable automation—aims to provide concrete solutions for the end-to-end production of cells, modules, battery packs, and e-Drive systems for the global market.
Related
• Comau has developed a flexible, industrialized cell formation and testing solution for NIC, bridging the gap between academic research and commercial battery development • The reconfigurable platform supports pouch, cylindrical and prismatic cells ranging from laboratory prototypes to high-power cells and industrial applications • Semi-automated processes, remote cell connection and integrated safety features help […]
• Comau and Intecells will showcase their innovative roll-to-roll battery cell surface treatment solution, based on field-proven cold plasma technology • By improving wettability of electrode and separator surfaces, the solution significantly reduces production time and energy consumption while helping improve cell performance • The joint development for battery and energy storage applications has potential […]
