Recently, top Chinese EV manufacturer BYD held a launch event in Shenzhen, officially unveiling its second-generation blade battery alongside the supporting ultra-fast charging technology. According to information released at the event, the core breakthrough of the new battery lies in its remarkable charging efficiency.
The ultra-fast charging capability and highly integrated structural design represented by this next-generation technology require higher precision and standards on module and PACK assembly processes. From structural reliability under extreme low-temperature conditions to consistency and traceability in large-scale mass production, every performance breakthrough depends on mature and deployable intelligent manufacturing solutions.
LeadTech, a subsidiary of Lead Intelligent Equipment (hereafter referred to as LEAD), has long focused on intelligent Li-ion battery assembly solutions. The company has established a full-process solution covering cell pre-processing, module assembly, PACK integration and end-of-line testing. Its capabilities span prismatic, blade, pouch, cylindrical and solid-state batteries, supporting both EV and energy storage applications while enabling the scalable industrialization of next-generation battery technologies.
Backed by years of technological accumulation and R&D investment, LEAD has built a core competitive edge centered on “platform empowerment + specialized expertise”, establishing a complete technological closed loop in intelligent battery assembly — from underlying algorithms to process control.
Built upon an integrated technology matrix combining “AI+3D vision + precision fluid control + integrated testing”, and further empowered by multimodal large-model industrial applications and digital twin simulation technologies, LEAD has developed an industry-leading intelligent assembly solution for blade battery module and PACK manufacturing. Covering key processes including module stacking, Busbar laser welding, low-voltage harness installation and top foam application, this solution precisely addresses next-generation battery manufacturing requirements across two core dimensions:
Precision for Better Battery Performance
Centered on a self-developed micron-level servo tightening system and the multi-sensor point-cloud stitching technology, the solution enables refined control throughout the entire production process from cell pre-processing to PACK integration.
The laser welding accuracy is controlled within ±0.02mm, effectively eliminating welding defects at the corners of short-blade cells. Cell stacking gap deviation is maintained within 0.1mm, ensuring the structural stability of ultra-thin composite aluminum foil cells while fundamentally reducing the risk of poor electrical contact under high-rate charging conditions. This provides a reliable foundation for stable battery performance.
Flexibility for Higher Efficiency and Quality
The solution fully supports intelligent module and PACK assembly for both blade batteries and prismatic batteries, while accommodating multiple process routes including CTM and CTP architectures.
Designed around the principles of “extreme mass production capability and stable reliability”, the solution achieves automation rates exceeding 90% in module assembly sections and over 70% across the full production segment. While significantly improving manufacturing efficiency, it also ensures process consistency and controllability.
Through the deep integration of modular design and rapid changeover technology, model switching can be completed within two hours. This not only supports large-scale production of short-blade cells, but also flexibly adapts to the increasingly complex customization of multiple vehicle platforms.
At the same time, the coordination of the full-process MES and RFID traceability assigns each battery cell a unique digital identity, enabling full lifecycle traceability from welding points to adhesive application. This establishes a robust data-driven quality assurance framework for the entire production chain.
As a core partner of multiple top battery manufacturers, LEAD has accumulated extensive technical expertise and GWh-scale mass production experience in this field. The company is committed to a fully integrated “cell-to-container” solution for blade batteries, covering cell pre-processing, module assembly, PACK integration and final testing, to support the rapid technological evolution of new-generation blade batteries.
Integrating flexibility, quality control, data management and intelligent manufacturing, the solution supports mixed-line production for multiple cell formats and automatically adjusts process sequences to accommodate diverse production requirements.
A full-process online inspection system combined with automatic defective-product rejection mechanisms establishes a comprehensive quality firewall from raw process stages through finished products. More than one hundred critical process parameters are automatically collected and archived, ensuring full-process traceability and data-backed quality assurance.
Meanwhile, standardized operating procedures and intelligent error-proofing prompts significantly reduce human error and redefine efficient operations.
Across key performance indicators, the production line delivers industry-leading intelligent manufacturing standards:
- Overall Equipment Effectiveness (OEE) ≥ 85%
- Process Capability Index (CMK) ≥ 1.67
- Measurement System GR&R ≤ 10%
From flexible production and precision quality management to data traceability and human-machine interaction, LEAD leverages its cutting-edge intelligent manufacturing capabilities to help customers reduce production line construction costs, shorten commissioning cycles and achieve simultaneous breakthroughs in both technological and commercial values.
As the new energy vehicle industry officially ushers in “1,000-kilometer range + five-minute fast charging”, LEAD, as a core upstream equipment supplier in the industrial chain, remains committed to technological innovation as its driving force.
Through robust performance metrics and multidimensional intelligent manufacturing advantages, LEAD continues to support the large-scale deployment of the world’s most advanced EV battery technologies. Looking ahead, we will continue working alongside industry partners to build a more sustainable future for the global new energy industry through forward-looking intelligent solutions.
