Challenge completedFuture-Proof Lead-Batteries: Non-Destructive Inline cell connector welding Inspection
Power the next generation of reliable vehicles. A leading battery manufacturer seeks a non-destructive, inline post-weld inspection that delivers fast, trustworthy pass/fail decisions at line speed. Help future-proof lead-acid batteries for functional-safety programs—and turn proven physics into a compact, production-ready solution with a clear path to pilot and scale.
Who can participate?
Startups, scale-ups, research labs, and industrial NDT providers with non-destructive inspection expertise (e.g., ultrasound), inline automation, and quality assurance.
Applicants must be able to validate on supplied samples and run a prototype-line pilot in the EU, with a clear path to EU Machinery Directive conformity and production integration or show when and how this will be possible in the future.
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.