Engineered to increase production capacity, improve manufacturing efficiency, and support the commercialization of next-generation energy storage technology
A leading energy storage technology company had developed a novel iron anode technology designed to support long-duration energy storage applications. While the underlying technology had demonstrated strong potential, the manufacturing process remained limited in scale and throughput.
The production process involved heating iron powder to approximately 900°C within an inert atmosphere furnace before transferring the heated material to a hydraulic press for compaction into finished electrodes. At the time of the project, production was limited to approximately one electrode per day, significantly constraining the company’s ability to support pilot-scale manufacturing and future commercialization efforts.
To meet growing production demands, the company needed a solution capable of dramatically increasing throughput while maintaining product quality, operator safety, and process reliability. The project also carried an aggressive timeline, requiring engineering, equipment sourcing, refurbishment, integration, testing, and installation to be completed within approximately six months.
The client partnered with Re:Build DAPR to evaluate manufacturing scale-up options, develop an optimized production solution, and deliver a fully integrated system capable of supporting pilot-scale operations.
Re:Build DAPR began the project by evaluating multiple manufacturing scale-up strategies and identifying the most efficient path toward increased production capacity.
The engineering team researched both new and used furnace and hydraulic press options, balancing throughput requirements, equipment availability, project cost, and schedule constraints. Detailed timing studies and process evaluations were conducted to determine the equipment configurations necessary to achieve production goals while minimizing implementation risk.
To validate system performance, Re:Build DAPR performed Computational Fluid Dynamics (CFD) analysis to determine furnace heating requirements and verify that the anodes could reach the required processing temperature within the available cycle time. Additional thermal, structural, and mechanical analyses were conducted to optimize material handling systems, evaluate equipment modifications, and ensure safe operation throughout the manufacturing process.
Throughout development, the team focused on creating a solution that improved production output while maintaining a safe and ergonomically efficient manufacturing environment for operators.
Re:Build DAPR designed and delivered a fully integrated manufacturing platform that combined refurbished equipment, custom-engineered subsystems, and upgraded controls into a scalable production process.
The solution incorporated a combination of new and refurbished furnaces along with an upgraded hydraulic press system. Re:Build DAPR refurbished the used furnace and press equipment, modernized controls, and implemented custom upgrades to meet the client’s production requirements.
Custom-designed gas control panels, pneumatic systems, and safety monitoring systems were integrated to support furnace operation and maintain a controlled processing environment. The team also developed a custom sensor array capable of monitoring potentially harmful gases generated during the manufacturing process, improving operator safety and process visibility.
To address the challenge of handling components at temperatures approaching 900°C, Re:Build DAPR modified a material handling cart with specialized lifting mechanisms that allowed operators to safely transfer heated anodes between the furnace and hydraulic press. Additional engineering work included custom insulation systems for the press, preventing heat loss during compaction and helping maintain process consistency.
The resulting system integrated furnace operation, material handling, pressing, controls, and safety systems into a streamlined manufacturing workflow optimized for increased throughput and long-term reliability.
Re:Build DAPR successfully delivered, tested, and installed the manufacturing system, enabling the client to dramatically expand production capacity within its pilot manufacturing facility.
The completed solution increased production capability from approximately one anode per day to an additional 36 anodes per day, representing roughly a 1,200% increase in manufacturing capacity. The upgraded process provided the client with the throughput required to support pilot-scale production while accelerating progress toward broader commercialization objectives.
Beyond production gains, the project delivered significant improvements in safety, ergonomics, equipment reliability, and process control. The integrated approach allowed the client to scale manufacturing rapidly while reducing technical and operational risk.
The project demonstrated Re:Build DAPR’s ability to combine engineering analysis, equipment integration, process development, and manufacturing scale-up expertise to help emerging energy technology companies transition from development to production.
The manufacturing platform included:
Let’s talk about your unique challenges and how Re:Build DAPR can help you.
