Which Technology Will Prevail? The Process Chain Makes the Difference.

The debate about the right separation process for aluminum battery cell housings is in full swing. Laser cutting, chipless cutting, sawing – every method has its advocates. But focusing solely on the cutting method means asking the wrong question.

Three Methods, No Clear Winner – Not Yet

Laser cutting scores with high format flexibility, but comes with challenges around non-productive times, peripherals and thermal effects. Chipless cutting enables very high output at constant dimensions – but reaches its limits when frequent format changes are required. Sawing offers a wide dimensional range, short changeover windows and robust cycle capability – provided the entire process chain is consistently designed around it.

The Real Question: What Keeps the Cycle Running?

In practice, cycle targets rarely fail because of the cutting method itself. The critical factors lie elsewhere: non-productive times and handling, tooling costs at second-cycle rates, reproducible deburring, and changeover times between formats.

"At second-cycle rates, it's not the individual process that decides – it's the stability of the entire process chain, including handling, tooling costs and deburring." — Thomas Berg, Managing Director Pressta-Eisele

Our Answer: One Line – Everything Included

Our fully automated production line covers the entire process – from raw profile infeed to the finished, ready-to-install battery cell housing. Key stations at a glance:

Automatic horizontal loading magazine – bundled infeed and precise alignment of raw profiles
Profilma 460 high-speed circular saw – oil-free cutting without coolants or lubricants, length tolerance ±0.1 mm
Linear outfeed axis – automatic transport, reliable separation of offcuts and remnants
Buffer conveyor with profile-specific nesting system – organized intermediate buffering
Laser marking station with two Keyence hybrid lasers – permanent marking with inline verification and MES connectivity
Rasamat Automat brush deburring machines – bilateral deburring, automatic brush compensation, fully integrated into central HMI
Parts removal table – manual or fully automated transfer to the next process step

The Numbers That Count

Parameter - Value
Cycle time: approx. 1.35 sec. per housing
Daily outputup to 50,000 units
Length tolerance ±0.1 mm
Technical availability94 %Line
dimensions approx. 20 × 6 × 5 m

Production readiness is not created by the cutting method alone – but by a consistently designed, fully integrated process chain. That is our approach.

Planning a battery cell housing production line or looking to automate your existing production? Get in touch – from feasibility analysis to turnkey line.

Directly to our solution.