Battery Lab Becomes Invaluable Industry Resource by Adding a Scalable Coating Line

You could consider the Rochester Institute of Technology’s Battery Development Center (BDC) to be the “jumpstart” that battery manufacturers need to scale their operation.

The BDC was created to “help companies develop the next generation of battery materials,” says the center’s director, Matthew Ganter, PhD. More specifically, it provides pilot-scale electrode manufacturing and prototyping to startups and small manufacturers.

But to keep pace with rising industry demand and maintain high-precision standards, the BDC required a scalable, roll to roll coating system that could function within a dry room environment—a capability not commonly found in other prototyping facilities.

Challenge

When the BDC first opened in 2015, initial funding allowed for the construction of a dry room and basic battery assembly equipment. However, the center lacked a small-scale slurry mixing and roll to roll coating line—a key capability for prototyping.

As a result, the BDC had to rely on external partners for these critical processes. This limited scalability and increased turnaround times for research projects. It also created challenges such as these:

Inadequate coating capabilities. “We could only coat on a meter-long sheet at a time, with small batches of battery slurry,” says Dr. Ganter.

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“The inability to scale was stretching our ability to keep up with demand.“

Matthew Ganter, PhD, Director of the Battery Development Center at the Rochester Institute of Technology

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Moisture-sensitive materials require a dry room setup. Many next-gen battery materials are highly sensitive to moisture. This meant the BDC’s processing had to occur in a controlled dry room environment to ensure consistency and viability.

High-precision slot-die coating was essential. It’s common for prototyping labs to use less precise methods like knife-over-roll. But to accurately replicate commercial-scale production, the BDC needed to achieve tighter tolerances and more uniform coatings.

Space and cost constraints. As a growing facility with limited lab space, the BDC wanted a compact, integrated solution that maximized functionality without requiring major facility modifications.

To meet these challenges and better serve the industry, the BDC sought a solution designed for precision, efficiency, and adaptability.

Solution

After securing more funding, the BDC vetted a number of vendors to design a coating system that would meet its specific needs. Ultimately, Delta ModTech was selected. Highlights of specific solutions provided to the BDC include the following:

A high-precision slot-die coating system integrated into a dry room. Unlike many prototyping labs that use lower-precision methods, the BDC could now coat materials with commercial-scale accuracy in a moisture-controlled dry room.

A compact, space-efficient design. To maximize lab space, Delta ModTech integrated a slitting unit directly into the unwind-rewind system, eliminating the need for separate equipment and reducing costs.

Flexibility for a wide range of coatings. The system includes two different coating heads—slot die and knife-over-roll—enabling the BDC to adapt to different projects and material types.

Exceptional process control and tight tolerance capabilities. The system delivers precise thickness control and uniform coatings, ensuring that researchers and manufacturers get consistent, high-quality electrodes.

Throughput

According to Dr. Ganter, since implementing Delta ModTech’s custom coating system, the BDC has expanded its industry influence and improved its ability to support battery development in multiple ways:

Scalability for industry growth. The ability to coat and slit electrodes at pilot scale has made the BDC a valuable resource for companies looking to test new chemistries without committing to full-scale production runs. “The demand has been so high that we’ve been booked nearly every day for the last three years.” 

Optimized efficiency and reduced costs. The Delta ModTech system has allowed the BDC to do everything in-house, cutting down turnaround times and eliminating the need and added costs of outside coaters.

A reliable partner for technical support and collaboration. Delta ModTech provides ongoing technical support, contributes to the BDC’s training programs, and shares coating expertise with visiting innovators. 

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“We didn’t just want to buy equipment from a vendor. We wanted a partner we were comfortable working with, someone who could help us enhance our impact on the industry. Delta has been that and more.”

Matthew Ganter, PhD, Director of the Battery Development Center at the Rochester Institute of Technology

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Looking Ahead

With growing industry demand, the BDC continues to expand, securing additional funding to enhance its equipment, lab space, and training programs. These advances will further support battery innovators in refining materials, scaling production, and accelerating commercialization.

Delta ModTech looks forward to continuing our support in helping the BDC drive battery innovation! a good partnership.”

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