Tesla’s 4680 Cell Production Process Described in Revised Giga Berlin Papers


Tesla’s revised documents for the Gigafactory Berlin have been posted online and are a wealth of information. The documents provided new details about Tesla’s 4680 battery plant at Gigafactory Berlin, which Elon Musk says is on the way to becoming one of the largest battery production facilities in the world. They also explained how Tesla’s 4680 cells are produced.

While sections of the dossier regarding the planned 4680 battery cell plant at Giga Berlin have been withheld due to sensitive information that could not be made public, the documents show some important information about the upcoming installation. . This includes the plant’s four-stage cell production operations, with anode and cathode production on the first stage and table-less cell production on the third stage. The battery factory is massive, requiring a large foundation similar to the Phase 1 area of ​​Gigafactory Berlin.

More importantly, Tesla also submitted a simplified diagram of its 4680 battery cell production process, although most of the diagram was blacked out in the public release of the revised dossier. However, the company gave a brief overview of how its new battery cell will be produced in the upcoming installation (approx. translated via Google Translate).

“The battery Gigafactory Berlin requires systems and stages of special processes. The anodes and cathodes are made of coated current collector sheets. Copper is used as a material for the anode foil and aluminum is used for the cathode foil. The anode and cathode components are manufactured using a combination of methods (A020-01 and A020-02), which use only powdered materials. The new materials are tested and approved in our own laboratory (A020-11).

“In order for the powder coating to adhere to these two films, they must first be pre-coated with a thin layer of adhesive (substrate) (A020-03 and A020-04). This substrate is delivered in containers. Pre-coating is necessary, as dry powder coating takes place. After the anode and cathode components have been mixed, they are applied as a coating on the respective coated substrate film in order to make electrical contact (A020-05 and A020-06). The current collector sheets, coated with the anode or cathode components, lead to the finished anode or cathode.

The revised documents also provided a general idea of ​​how Tesla’s table-less cell production works. Among these was the fact that the finished 4680 cells would be subjected to 10 days of curing after their formation.

“The anode or cathode is then cut to the required lengths with a laser in the“ no-table process ”(A020-08). The anode, cathode and separator are alternately placed on top of each other and wound into a roll. This roll is then inserted into a metal casing, which is made from steel rolls in a stamping and stamping process (A020-07). In the assembly area, final assembly and filling of the cell takes place with small amounts of electrolyte (approximately 10% of the cell weight) (A020-09).

“The electrolyte is absorbed by the coatings of the electrodes and allows lithium ions to move between the anode and the cathode. The housing is then closed with a cover in a welding process. The last step is the formation (A020-10) of the cell. In the forming process, the cell is electrically started by charging and discharging it under different temperature conditions. The finished cell remains in this area for approx. 10 days and is then reused. The cells produced are subjected to a random quality control in our own laboratory (A020-11).

A link to the Tesla files for Gigafactory Berlin could be found here.

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Tesla’s 4680 Cell Production Process Described in Revised Giga Berlin Papers


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