In the transition to sustainable energy systems, innovation does not stop at new chemistries. It must extend into the manufacturing process itself. For one clean energy client, a novel iron anode held the promise of scalable, low-cost energy storage. But with a complex production method involving 900°C processing and a throughput of just one electrode per day, scale-up was a major bottleneck.
This is where Re:Build DAPR stepped in. In just six months, we engineered, sourced, integrated, and validated a custom manufacturing solution that increased daily output by more than 1,200%, growing from 1 to 37 anodes per day. The result was a pilot facility ready to support commercialization and deliver a truly scalable clean energy solution.
This blog outlines the engineering challenges, system integration strategies, and tools we used to bring this custom process online at scale.
Our client had developed a novel iron anode designed for next-generation energy storage, but the fabrication method behind it was far from conventional. The process began with heating fine iron powder to 900°C in a tightly controlled, inert gas environment to prevent oxidation and ensure the material’s chemical integrity. Once at temperature, the material needed to be rapidly and safely transferred to a hydraulic press, where it underwent uniaxial compaction into a dense, high-performance electrode.
Each step in this sequence presented unique thermal, mechanical, and environmental challenges. The system required precise timing to avoid heat loss, careful control of atmospheric conditions, and robust handling solutions for components nearing 1000°C. Material degradation, inconsistent compaction, or exposure to ambient air could jeopardize product quality and operator safety.
At the time of our engagement, the client was operating at minimal throughput, producing just one anode per day, five days a week. Their goal was ambitious: to scale this lab-scale process into a pilot production line capable of producing more than 30 anodes daily. To do so, they needed not only new equipment, but also a reimagined process architecture that could preserve safety, consistency, and performance at much higher volumes.
Scaling a highly specialized process required more than simply adding capacity. It demanded a carefully engineered solution that accounted for extreme temperatures, spatial constraints, operator safety, and tight production timelines. Our team began by conducting a comprehensive evaluation of available equipment, including new and used options, to determine the best-fit solution for the client’s unique needs.
We assessed each furnace and press based on several key criteria: thermal uniformity, compatibility with inert gas environments, cycle time, load handling capability, and integration flexibility. Leveraging CFD simulations and timing diagrams, we analyzed heat-up curves, calculated energy requirements, and modeled cooling behavior to validate each piece of equipment before procurement.
Based on this analysis, we recommended and secured the following:
Each unit was carefully matched to the process flow and engineered to operate in sync with surrounding systems. This hybrid approach allowed us to maximize performance and minimize cost, while meeting the client’s aggressive production ramp timeline.
Procuring the right equipment was a critical first step, but real operational value came from integrating those components into a fully functional manufacturing line. This required coordinated design, safety engineering, and process optimization to ensure that all systems could work together under demanding thermal and mechanical conditions.
Our engineering team designed and delivered a suite of custom subsystems to support efficient, repeatable production:
To support safe movement and consistent positioning of the heated components, we also engineered fork cart mounts and tipping mechanisms tailored to the anode’s geometry and weight distribution. These features were not only critical for protecting operators, but also for maintaining high throughput under thermal stress. All mechanical modifications were validated using SolidWorks for geometric design, FEA for structural load analysis, and Mathcad for calculation checks and tipping point verification.
From the earliest stages of the project, simulation and modeling tools played a central role in guiding design decisions, validating concepts, and reducing project risk. Rather than rely on trial-and-error during installation, we built a comprehensive virtual understanding of how the system would behave under real-world conditions.
Our digital toolset included:
These tools generated critical insights, including:
By integrating simulation early and throughout the design process, we were able to tailor every mechanical and thermal interface to the client’s exact process parameters. This approach enabled faster implementation, better performance, and safer operations from day one.
The outcome of the project was both measurable and transformational. In just six months, the client scaled from producing one iron anode per day to 37, representing a twelvefold increase in output. This leap in capacity positioned their pilot facility to actively support commercial objectives and fulfill growing demand for their innovative energy storage solution.
In addition to increasing throughput, the integrated system delivered several critical operational benefits:
Ultimately, the project demonstrated how targeted engineering, rooted in simulation and precision integration, can bridge the gap between promising lab-scale technologies and real-world production. It also highlighted how Re:Build DAPR’s systems approach helps bring unconventional manufacturing processes to industrial scale.
Not every breakthrough in clean energy happens inside the cell. Often, it is the engineering behind the manufacturing process that determines whether a technology scales or stalls. Turning a high-potential concept into a commercially viable product requires as much innovation in the production line as in the chemistry itself.
At Re:Build DAPR, we specialize in solving these types of complex, system-level challenges. From thermal energy storage and cryogenic systems to superconducting components and advanced materials processing, we help organizations design and deploy custom solutions that are both technically sound and built for scale.
If your team is developing a novel process or preparing to scale a unique product, we welcome the opportunity to collaborate. Let us help you move from prototype to production with confidence.
Looking to connect with an experienced team?
Look no further than Re:Build Optimation! We are excited to connect with you.
