Partner Presentation: Battery Pack Scale-Up: From Prototype to Series Production

Tuesday, 23 June 2026

Scaling battery pack manufacturing from prototype to full-scale production requires far more than core battery expertise. It demands the integration of multiple advanced engineering disciplines to ensure precision, quality, and repeatability at every stage of the process.

In this talk, Clayton Sampson explores the complexities involved in transitioning from low-volume assembly to high-volume, automated production of battery modules and packs. The session highlights critical factors often overlooked, including part cleanliness, surface preparation for adhesives, precision component placement, de-oxidisation prior to laser welding, and the fine control of laser weld parameters such as power, positioning precision and critically important weld depth.

Drawing on real-world experience supporting automotive and aerospace manufacturers, the talk showcases how the combination of robotics, automated assembly, tooling, and vision systems alongside specialist processes such as plasma treatment, laser ablation, and laser welding enables scalable, high-quality production solutions.

Additionally, the role of data acquisition and handling in maintaining rigorous process control will be explored, demonstrating how digital integration underpins consistent manufacturing outcomes.

Attendees will gain an understanding of the interdisciplinary approach required for successful battery pack scale-up, along with practical insights into building robust, turnkey production systems. The session also provides perspective on how Cyan Tec is positioning itself as a complete solution provider for organisations developing advanced battery manufacturing capabilities.