Why Choose Polymer Batteries?

Polymer cells are widely used for their high packaging efficiency (90–95%), lightweight structure, and flexible design. They offer high energy density and excellent space utilization, making them ideal for EVs, energy storage, consumer electronics, and drones, with more compact and adaptable pack designs than cylindrical and prismatic cells.

Common Equipment in the Production Line

The polymer battery pack assembly line typically involves the following key machines:

Grading Machine

Sorting Machine

Tab Cutting Machine

Ultrasonic Welding Machine / Laser Welding Machine

Comprehensive Tester

BMS Tester

Aging Machine

Process Breakdown of Semi-Automatic Line

Semi-automatic lines combine manual operation with automated stations, providing a flexible and cost-effective solution for polymer battery module production.

They are especially suitable for multi-model, small-to-medium scale manufacturing, where frequent product changeover is required.

Step1: Polymer Cell Capacity Testing

The grading machine is used to test cell capacity through charge and discharge cycles. Only qualified and well-matched cells proceed to the next stage, ensuring improved module performance and long-term consistency.

Polymer Battery Capacity Grading Machine
Model	5V 10A	5V 20A	5V 30A	Customized
Channel	1 / 2 / 4 / 8 / 128 / 256 / 512 / Customized
Clamp	open-close clamping fixture with a tray-based design

Step2: Polymer Cell OCV&ACIR Sorting

The sorting system detects each cell’s voltage and internal resistance, automatically classifying them into different channels based on preset value ranges. Cells that do not meet any defined criteria are directed to the NG channel for rejection. This process ensures consistent cell grouping and improves overall module reliability.

Prismatic Battery Sorting Machine
Barcode Scanner	Keyence or standard Chinese-made
Tester	HK3561/HIOKI Optional
Sorting Channels	7+1=8CHS	9+1=10CHS	Customizable

Step3: Polymer Tab Cutting

The tab length cutting process is used to precisely trim both positive and negative tabs simultaneously, ensuring consistent tab length for each cell. The equipment is designed with a safe cutting mechanism that prevents short circuit during operation, improving both accuracy and process safety.

Step4: Polymer Cell Loading & Welding

For polymer battery module welding, two options are available: ultrasonic welding and laser welding. Ultrasonic welding uses high-frequency vibration to join materials and is well-suited for soft or thin materials, while laser welding utilizes a high-energy laser beam and is more suitable for thicker busbars or rigid conductive structures. The selection of welding method depends on the customer’s battery design and structural requirements.

Polymer Battery Welding Machine
Machine Type	Ultrasonic Welding	Laser Welding
Machine Model	20–40 kHz	1500W / 2000W / 3000W
Welding Principle	High-frequency vibration friction	High-energy laser beam melting
Suitable Materials	Soft / thin materials (Al/Cu tabs)	Thick materials / busbars
Heat Effect	Low heat impact	Localized high heat input
Welding Fixture	Optional	Required
Module Picture

Step5: Polymer Battery Pack BMS Testing

The BMS testing system is used to verify the protection, communication, and electrical performance of battery management systems in assembled packs, ensuring safe and stable operation.

Main Features

Overcharge / Overdischarge protection test

Overcurrent / Short circuit protection test

Temperature protection test

Internal resistance & conduction resistance testing

Self-consumption detection

Communication function verification (CAN / RS485 / I2C) for accurate reading of SOC, voltage, temperature, and other data

Battery Management System Testing Machine
Pack Series	1-52S Battery Pack/Module
Current	120/150/200/300/400/500/600/800A etc		Customizable
Computer	Without computer	With computer

Step6: Polymer Battery Pack Comprehensive Testing

The battery comprehensive tester is suitable for all lithium-ion battery packs with CH+, P+, CH-, P- ports and is used to evaluate the overall electrical performance and reliability of battery packs. It applies a load or small AC current to measure key parameters such as open-circuit voltage, AC internal resistance, discharge characteristics, discharge overcurrent protection, short circuit protection, charge performance, and charge protection. By setting upper and lower limit values for each parameter, the system can quickly identify and screen out defective batteries from a batch of finished products, ensuring stable and reliable quality control.

Battery Pack Comprehensive Tester
Voltage Range	50/60/100/120V/200V etc			Customizable
Current Range	120/200/300/500/600A etc
Machine Picture

Step7: Polymer Battery Pack Aging Testing

The battery pack aging machine is designed for cycle aging tests, functional performance evaluation, and real-time monitoring of charge and discharge data. It supports four test modes including charging, discharging, shelving, and cycling, allowing flexible program configuration to simulate real working conditions and comprehensively evaluate battery stability and reliability.

Battery Pack Aging Testing Machine
Voltage	20V-1650V
Current	10A-1200A
Channels	1/2/3/4/6/7/8/12/16/32 etc
Type	Standard type/with energy regenerative function (optional)
Standard Model	30A 10A 20-12CH	85V 10A 20A 7-CH	100V 20A 40A	Customized
Machine Picture

Process Breakdown of Full Automatic Line

The fully automatic module and PACK production line covers the entire process from cell loading, cell testing, and cell taping to module assembly, module welding, and module testing, enabling a fully automated and continuous production workflow from cell to finished battery pack.

Production Line Process Flow

Polymer Battery Application

Polymer battery packs are increasingly widely used across energy storage systems, electric vehicles, and portable electronic devices, driven by their high energy density, lightweight design, and flexible application adaptability.

Contact us to get a complete customized solution.

Contact Us

Xiamen Tmax Battery Equipments Limited

Global Head Office

Email: David@tmaxcn.com

Email: Davidtmaxcn@gmail.com

Tel：+86 13174506016

WhatsApp:+86 18659217588

Wechat: 18659217588

Xiamen Address:  Building 1, No. 39 Xinchang Road, Haicang District, Xiamen City, Fujian Province, China