Future-Proof Lead-Batteries: Non-Destructive Inline cell connector welding Inspection

What is the company looking for?

Modern vehicles rely on a resilient 12V backbone to keep key functions responsive—through starts, stops, and high-load events. In lead-acid batteries, the tiny interface where cell connectors are welded is mission-critical: if every weld is sound, performance is predictable and certification is straightforward.

A leading battery manufacturer is advancing this reliability with a non-destructive, inline cell connector welding inspection that delivers clear OK/NOK (Pass/Fail) decisions at line speed. The target: ≤30 seconds total cycle in a ~1×1 m station, reaching ppm-level quality for functional-safety programs. The company is open to all viable testing technologies such as ultrasound. X-Ray technology is specifically excluded as it does not scan through lead metal material.

Why participate?

Collaborate with a leading battery manufacturer on a tightly scoped, implementation-oriented brief - flexible to your stage, yet focused on real impact.

• Discovery & Fit (optional, short): Align on your approach, access constraints (post-weld, pre-lid), footprint (~1×1 m), and cycle-time targets (≤30 s). The final target for testing is max.11s per battery. Share what’s ready now and what needs co-development.
• Step 1 - Validation (PoC): Validate your method on OK/NOK samples supplied by the company, proving accurate OK/NOK classification (benchmarked against destructive ground truth).
• Step 2 - Paid Pilot (prototype line): After successful validation, run a paid pilot on the prototype line in Germany/EU to demonstrate inline performance (≤30s total cycle, with final target of ≤11s, ~1×1 m station) and integration readiness.
• Clear success bar: Meet OK/NOK accuracy, ppm-level targets, EU Machinery Directive conformity, and PFAS-free media requirements.
• Co-development where useful: Provide automation/fixturing and a parallelization concept to meet takt.
• Long-term opportunity: Successful pilots can progress to production rollout, ongoing supply/service agreements, or joint development.

What to submit now:

A concise PoC + Pilot plan mapping your current maturity (e.g., research prototype, (near-)ready system), sample/testing needs, validation metrics/report format, and a draft offer for the paid pilot (scope, milestones, timeline, costs) contingent on PoC success.