As square battery packs hold a 77% domestic market share (2025 industry data), is your production line facing these three critical challenges:
✅ High costs – Reliance on imported pouch aluminum film drives up material costs by 30%?
✅ Technical bottlenecks – Can’t break the 95% welding yield barrier for 4680 cylindrical cells?
✅ Scenario mismatch – Forced to compromise on energy density by using square cells in high-end vehicles?
As a leading Chinese intelligent manufacturing expert with 15 years of deep experience in battery pack assembly lines, we reveal the technical truths to help you overcome these challenges—
(Check the "Cost-Efficiency Comparison Table for Square/Cylindrical/Pouch Assembly Lines" at the end!)
Square Battery Pack Assembly Line: The "Flexibility Master" Behind the National Bestseller
▸ Core technology: Dual-track winding and stacking, aluminum shell laser welding with ±0.1mm precision
▸ Bestseller genes: Customizable for blade/long cells, energy density increased by 20% (e.g., BYD’s CTB technology)
▸ Production line advantages: Modular hot press forming machines + AI visual inspection, changeover time reduced to 15 minutes
Ideal for: Cost-effective passenger vehicles (e.g., mainstream ¥100k-200k models), daily production capacity ≥50,000 units
Cylindrical Battery Pack Assembly Line: The "Speed Monster" Popularized by Tesla
▸ Revolutionary breakthrough: 4680 large cylindrical full-tab welding technology, single-line speed exceeding 300 PPM (twice the industry average)
▸ Cost advantage: Standardized cells + spider robot stacking, module costs reduced by 40%
▸ Pain point solved: Nano-copper welding process overcomes shell strength limitations, yield stabilized at 98.5%+
Ideal for: High-performance vehicles with 600km+ range (e.g., CyberTruck), ideal for large-scale production
Pouch Battery Pack Assembly Line: The "Invisible Champion" of the High-End Segment
▸ Breaking import dependency: Self-developed nano-coated aluminum film, stamping efficiency increased to 0.8 seconds per piece (matching Japanese and Korean standards)
▸ Technological foresight: Pre-embedded solid-state battery process, energy density surpasses square cells by 5-10% (tested data)
▸ Automation revolution: Linear dual-station top sealing machines, fully eliminating manual stacking
Ideal for: Luxury electric sports cars (e.g., Lucid Air), medical device power supplies
Ultimate Selection Formula: Find Your Match and Save Millions
| Key Metrics | Square Line | Cylindrical Line | Pouch Line |
|---|---|---|---|
| Investment per GWh | Medium-High ★★★ | Low ★★☆ | High ★★★★ |
| Production Speed | Medium 120 PPM | Extreme 300 PPM | Low 80 PPM |
| Technical Scalability | Compatible with blade/CTP | Adaptable to 4680/4695 | Supports solid-state batteries |
| Recommended Scenario | Bestseller family cars | High-volume performance vehicles | Premium flagship vehicles |
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