Helping Battery Start-Up Companies Move from Concept to Commercialization

In battery innovation, great ideas may stall—or even die—before they can scale. But not if the Battery Development Center has anything to say about it. 

“We help companies get across the valley of death—from early lab-scale research to production-ready materials and processes,” says Matthew Ganter, PhD. He directs the BDC, which is based at the Rochester Institute of Technology.

Find out below how the center helps start-ups and researchers move from concept to commercialization—providing specialized tools, hands-on training, and critical manufacturing capabilities.

Pilot-scale capability without the huge investment

Launched in 2015, the BDC was created to help companies develop next-gen battery materials. More specifically, it offers pilot-scale electrode manufacturing and prototyping services that enable start-ups and small manufacturers to refine their designs and move toward production readiness—without the burden of capital equipment investment.

According to Ganter, what truly sets the BDC apart is its ability to replicate commercial-quality battery production within a controlled dry room environment. This is especially critical for working with advanced chemistries, including moisture-sensitive materials used in cutting-edge lithium-ion and solid-state batteries.

While many prototype labs rely on lower-precision methods, BDC’s high-precision slot-die coating system mirrors the quality and control of full-scale facilities.

That system was custom-designed by Delta ModTech to meet the center’s unique requirements. With integrated slitting capabilities and interchangeable coating heads, it supports rapid iteration, precise process control, and real-world simulation at pilot scale. (Check out this case study for more details.)

Training the next generation of battery innovators

Equally important is the BDC’s commitment to workforce training and industry education. Through hands-on, two-day seminars and longer-term coursework, participants gain practical experience with commercial-grade tools and processes.

“We bring in speakers from across the industry to teach how to go from research scale to pilot to production,” says Ganter. “Then we get participants into the lab to work directly with the equipment. That’s where the real learning happens.”

By combining pilot-scale capability with real-world training, the BDC fills a critical gap in the battery innovation ecosystem—helping both companies and individuals prepare for the demands of scaling advanced energy technologies.

Providing a bridge from the lab to the production line

Ganter explains that many early-stage companies and research teams hit the same wall: their materials look promising at the lab phase, but falter when moved to production. That’s because scaling requires more than just chemistry—it demands equipment, environmental control, and process expertise.

But at the BDC, companies and organizations can test, iterate, and optimize their electrode coatings under real-world manufacturing conditions. The facility’s integrated systems and tight process tolerances allow companies to prototype with confidence—knowing their materials are being validated under conditions that closely mirror scaled production.

In constant use—and still expanding

With its combination of pilot-scale manufacturing, precision coating capabilities, and immersive instruction, the BDC has become a go-to destination for battery innovators. Ganter says its slot-die coating line has been in near-constant use, booked almost daily over the past three years by start-ups, researchers, and manufacturers alike.

That sustained demand led directly to the BDC’s most recent expansion. The center secured $2.2 million in funding from New York State to double its lab space, add a second dry room, and scale its capacity for high-precision coating projects. 

This investment reflects how essential the BDC has become for companies looking to validate materials, optimize formulations, and move quickly toward commercialization.

Building the future of battery innovation

With energy storage playing a larger role across industries, the BDC is positioning itself for long-term impact. The expansion will support a wider range of chemistries, more complex production scenarios, and an increased volume of training opportunities.

As new technologies move from research to reality, the BDC will remain a vital launchpad—supporting innovators through the critical transition from feasibility to manufacturability. And through technical partnerships and workforce development, it’s helping to shape the next chapter in scalable battery innovation.

Delta ModTech is proud to support the BDC with coating technology and expertise that help advance the battery technologies of the future. 

If you have a product you’re developing or manufacturing, contact Delta ModTech to see how we can help improve your process.

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