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Capabilities

Whether you have a new material for a battery, need to test an energy storage device, or have an advanced energy idea; the BIC is here to support you. The facility is designed to be a highly flexible and IP secure. Every statement of work is catered to our client’s specific needs, and we continue to push the barrier on our capabilities. As an IP secure facility, we have no interest in accumulating Intellectual Property, so you can rest assured that your critical information, data, and product belong to you.

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Key Focus Areas

Battery Manufacturing

Test and Eval

Technical Consultation

Battery Manufacturing

The Battery/Cell Manufacturing Team are experts in producing multiple battery cell types (i.e. 18650, Coin, and Pouch/Prismatic). The BIC is setup with all of the tools needed to make the slurry and electrolyte, coat anodes and cathodes, slit/cut anode and cathode into the proper size and shape, and full cell assembly.

We provide a variety of expertise in the development of a battery. Routinely, we work closely with clients on the development of a material (i.e. anode material, cathode material, electrolyte, etc.) to determine both the viability of the material and potential chemistry pairing for the other cell components. We also assist with the development of a manufacturing process, to decrease downtime for deployment at a full-scale manufacturing facility. 

18650 Winder
The 18650 Winder winds anode, cathode, and separator. This produces tight jelly rolls for 18650s. There is the option to use different mandrels for different form factors, as needed.
Slitter
Tensioned line
3 adjustable blades (top and bottom) for cutting to various widths
Clean cuts
Electrolyte Filler
This device allows efficient repeatable electrolyte filling of cells, utilizing a series of metered vacuum, fill, and pressure application steps to fully infiltrate the entire cell with electrolyte. Tightly packed form factors, with a great deal of electrode surface area, like 18650s, need this to function at their full capacity.
Dryer and Coater
The Megtec Integrated Coating & Drying Webline has a high throughput and continuous electrode fabrication.
Calender
Continuous calendering with temperature control
Calendering is often necessary to reduce the porosity of coated electrodes in order to optimize electrolyte infiltration, electronic, and ionic conductivity
18650 Necker
This device creates the indentation "neck" in 18650 canisters necessary for sealing after the cell has been inserted.
18650 Crimper
This device permanently seals the caps of 18650's in place.
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Test and Eval

The Test and Eval Group has a large array of testing capabilities, which include testing battery cells to full-scale battery systems. The team has the capability to perform testing under a variety of environmental conditions, which include temperature, altitude, and humidity control. Electrically, the batteries can be programmed to perform any length of test protocols, which can include cycle life and application specific profiles.

A variety of AC test equipment, for inverters and other power electronics, is also located at the facility. BIC can currently test up to 180kW systems for AC input and up to 200kW with an AC load bank. The frequency and power factor are completely customizable to perform a variety of tests. A ring (surge) generator of up to 2kV and various meters are also available.

BIC also has all of the equipment to perform a variety of abusive tests, which include but are not limited to:

1. Nail Penetration

2. Over Charge

3. Over Heating

4. Forced Internal Short Circuit

5. Forced Discharge

All of this equipment is used for a variety of standardized testing, which includes UL, IEC, UN DOT, USABC, and Mil standard tests. Through a close relation with Underwriter’s Laboratory (UL), we can work with their on-site team to certify and test your device. As a part of this, we can offer pre-certification testing and consulting to ensure that you are ready, prior to starting the certification process.

THOR
Designed in collaboration with Technology Service Corporation (TSC), THOR is the BIC's test automation platform, which allows its personnel to use a single user interface to communicate with several pieces of equipment. Its capabilities include executing extremely complex custom profiles to each system, from the command center. Auxiliary data acquisition modules are used to provide additional channels for parameter recording (i.e. multiple voltage, temperature, and current values).
Chroma Grid Simulators
The Chroma AC Grid Simulators create a localized grid, for test grid tied assets. The system is capable of adjusting the various parameters to simulate a variety of situations on the grid. Some of their features include programmable voltage, frequency, and power output. Each system is capable of up to 60kW. With the master-slave configuration the BIC is able to test at up to 180kW.
Qunling AC Load Bank
The Qunling AC Load Bank is capable of providing a load of up to 200kW. It has banks of inductors, capacitors, and resistors which allow it to perform a programmable power factor of -1 to 1.
OAI Solar Simulator
The OAI solar simulator provides simulated solar radiation and tests photovoltaic cells up to 300mm x 300mm for power output and efficiency. The beam intensity is variable between 0-1000W per square meter, or 0 to full, direct sunlight.
Solartron
The Solartron has 8 channels that are designed for small battery cells. 4 channels can do impedance measuring as well as voltage/current profiles. Its smallest current resolution is 10uA and has a maximum reading frequency of 10,000Hz (10,000 values per second). The Solartron can perform profiles ranging from -4A to +4A and -3V to 10V with a max power rating of 40W.
Arbin
The Arbin has 32 channels that are designed for testing small battery cells. Each Arbin channel is capable of profiles ranging from 10mA to 5A and 0V to 5V. The Arbin has a resolution of 10mA.
Maccor 4000
The Maccor 4000 is a 24 independent channel system, which is capable of up to 120A and 5V per channel. The system is capable of line loss compensation of up to 5V to ensure a proper voltage supply to the battery under test.
Maccor 4000H
The Maccor 4000H is a 48 independent channel system, which is capable of up to 50A and 5V per channel. This system has a voltage compensation of up to 5V for line loss, to ensure that the appropriate voltage is applied to the battery under test.
NHR/TDK Cabinets
The NHR loads and TDK power supplies allow us test up to 16 channels at once, with a maximum current of 120A and a maximum voltage of 12.5V on each channel. Each channel can be programmed to run a separate profile, but all 16 can also be paralleled for up to 1920A and 12.5V.
Bitrode
The Bitrode has 16 channels that are designed for testing small to mid-sized battery cells. Each Bitrode channel is capable of profiles ranging from -100A to +100A and 0V to 5V. All 16 channels on the Bitrode can also be paralleled to give testing capabilities from -1600A to +1600A and 0V to 5V. The Bitrode has a resolution of 10mA.
MT-30
An electrical vehicle test system that is capable of performing any profile that ranges from 0A to 500A and 5V to 120V. The max power charge/discharge capability of this unit is 30kW. We currently have 8 MT-30’s that can be paralleled.
ABC-170
A medium sized electric vehicle test system. The ABC-170 is capable of profiles ranging from -640A to +530A, 5V to 445V, and -170kW to +125kW. We currently have 2 ABC-170’s that could potentially be paralleled.
AV-900
Our largest electric vehicle test systems. The AV-900 is capable of running profiles ranging from -999A to +999A, 10V to 900V, +/-250kW. We currently have 2 AV-900’s that can be paralleled.
CA-16 Altitude Chamber
Our CA-16 Altitude chamber was manufactured by CSZ. It is capable of profiles ranging from 0 ft. to 100,000 ft. and -45C (-49F) to 190C (374F). The temperature can only be regulated up to 50,000 ft.
ZPS 8 Temp/Humid Chambers
Our ZPS-8 chambers, from CSZ, is capable of temperature profiles ranging from -45C (-49F) to 190C (374F). We currently have 7 chambers that can only control temperature and 1 chamber that is able to control temperature and humidity. All 8 of these chambers have fire suppression systems hooked up internally, as well.
Webber 125
The Webber 125 is our largest chamber. It is only capable of temperature profiles, which range from -40C (-40F) to +177C (350F). The dimensions of the chamber are 5ft. x 5ft. x 5ft.
Webber 27
The Webber 27 is only capable of temperature profiles, which can range from -40C (-40F) to +177C (350F). The dimensions of the Webber 27 are 3ft. x 3ft. x 3ft.
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Technical Consultation

The BIC’s Technical Consulting Team is available to provide input in a variety of applications. Between the in-depth experience in the industry and a vast network of experts, we can assist with almost any energy related project. A sample of some of the common projects with have assisted on include:

  • Battery Management System (BMS) Design
  • System Architecture Design
  • Product Performance and Safety Review
  • 3rd Party Validation
  • Market Analysis
  • Energy Focused Facility Design
  • Internal and External Procedure Development
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