Design and fabrication of Lithium-Ion pouch cell folding machine: A case study on Zimbabwe's emerging battery industries

Zimbabwe is endowed with significant lithium reserves, establishing the country as an important player in the global Lithium-ion battery (LIB) supply chain. However, a critical challenge is the lack of local battery manufacturing capabilities, which restricts value addition in this emerging sector. This paper presents the design and fabrication of a specialized Lithium-ion pouch cell folding machine aimed at enhancing Zimbabwe's nascent battery manufacturing industry. The machine effectively addresses essential gaps in local production by enabling automated, high-precision electrode folding, which is a crucial step in pouch cell production. Utilizing locally sourced materials wherever possible, the prototype demonstrates a folding accuracy of ±0.15 mm and achieves a production rate of 15 cells per minute, making it suitable for small-to medium-scale battery assembly operations. Economic analysis suggests that implementing such machinery could reduce Zimbabwe's reliance on imported battery components by as much as 40%, thereby fostering industrial growth and creating employment opportunities within the country. This advancement not only strengthens the domestic battery industry but also aligns with broader economic development objectives.