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Industry

Batteries & Energy Storage

Every plant already has dashboards. Dashboards tell you what happened.

The expensive gap is the next four questions, and today they take a senior process engineer two to six weeks: why did it happen, what should I set the process to, can I trust the data I am about to decide on, and what should I run next. Niobia answers those against your own process history.

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The four questions

What a coating pinhole costs you three weeks later.

Why did it happen?

A coating pinhole at 1.2 m/min shows up as voltage fade three weeks later in formation. The correlation you can see is rarely the cause. Niobia traces the defect back through the process record to the stage that actually produced it.

What should I set the process to?

Not just a setpoint, but how wide the window is. Comma gap, solid content, line speed, and calendering pressure interact, so a number that works at one loading fails at another.

Can I trust this data?

Before a scrap decision rests on a measurement, gauge R&R and capability analysis tell you whether the gauge can even see the signal you are charting.

What should I run next?

Has someone already run this experiment? DOE design against your existing history, so the next build answers a question the last forty did not.

By manufacturing stage

Depth at every stage of the cell line.

Lithium-Ion Cell Manufacturing

Formation, aging, and final test: full cell genealogy

Anode Manufacturing

Coating, calendering, slitting: graphite, silicon, Nb₂O₅

Cathode Manufacturing

Slurry, coating, drying, calendering: NMC, LFP, NCA

Electrolyte Manufacturing

Mixing, filling, QC: liquid and dry electrolytes

Battery Recycling & Second Life

Black mass, hydromet, sorting: from pack to precursor

Flow Cell Manufacturing

Stack assembly, membrane QC, electrolyte handling

By chemistry

Beyond lithium-ion.

Lithium-Sulfur Batteries

Sulfur sublimation, polysulfide handling, high-loading cathodes

Sodium-Ion Batteries

Hard carbon, layered oxides, Prussian white outgassing

Solid-State Batteries

Sulfide moisture reactions, sintering camber, compression cracking

Supercapacitors & EDLC

BET surface area spread, ESR variability, electrolyte wetting

Fuel Cells

CCM defect rates, IR thermography, stack traceability

Methods used here

The analytical methods this industry leans on

How to read a Nyquist plot, and see a cell age in real time

A practical guide to the EIS Nyquist plot: the high-frequency intercept (Rs), the charge-transfer semicircle (Rct), the 45° Warburg tail, the Randles circuit, and how a growing semicircle reveals cell aging.

Charge/discharge curves and CCCV, reading a cell's voltage profile

How to read galvanostatic charge/discharge curves: voltage plateaus and what they mean, the CCCV protocol and its constant-voltage taper, coulombic efficiency, and how capacity fade shows up cycle over cycle.

GITT and PITT, getting a diffusion coefficient out of a battery

How the galvanostatic and potentiostatic intermittent titration techniques (GITT/PITT) work: the pulse-relaxation staircase, why the relaxation transient carries the diffusion coefficient, and how D varies with state of charge.

Central composite design, fitting curvature without running everything

How a central composite design works: the factorial cube, axial (star) points, and center points, why they let you fit curvature with a quadratic model, rotatability and alpha, and how CCD compares to Box-Behnken.

Cp vs Cpk, why a centered process is not the same as a capable one

What Cp and Cpk actually mean, how to calculate them, why Cpk collapses when a process drifts off-center while Cp stays constant, the capability thresholds, and common mistakes.

Related reading

Go deeper on battery manufacturing.

The gigafactory yield gap: US vs China The AI architecture for battery manufacturing AI vision for electrode coating inspection We ran real battery data through Claude and Gemini

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