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Cell Fabrication &
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Coin & Pouch Cell Fabrication and Electrochemical Testing
Accelerate Your Energy Storage R&D with NEI
For over two decades, NEI Corporation has been a trusted partner in advanced materials synthesis, electrode processing, and electrochemical characterization. Partnering with NEI for your cell fabrication and testing needs offers distinct strategic advantages:
Efficient Turnarounds & Strict IP Protection
We work closely with your team to establish clear timelines, ensuring prompt deliverable schedules. All work is conducted under strict Non-Disclosure Agreements (NDAs) to guarantee that your proprietary formulations, material samples, and testing data remain 100% protected.
Cost-Effective & Flexible Solutions
Save time and capital without the burden of internal infrastructure investments. We adapt seamlessly to your project milestones and budget, offering full-service R&D partnerships or per-sample fabrication and testing.
Bridging the Commercialization Gap
From battery chemistry fundamentals & feasibility testing in coin cells to application specific verification of multilayer pouch cell prototypes, our material-centric approach to electrochemistry can aid your project toward commercialization faster and more effectively.
Coin Cell FabricationPouch Cell FabricationCell-Level TestingAreas of ExpertiseRelated ServicesRequest a Quote
Coin Cell Fabrication Services
NEI provides comprehensive and reliable coin cell fabrication services tailored to the unique needs of battery material researchers and developers. Leveraging our deep expertise in advanced materials and electrochemistry, we assemble coin cells under controlled environments, ensuring the integrity and performance of your novel materials for accurate electrochemical testing and analysis. Partner with us to accelerate your battery R&D with high-quality, reproducible coin cells.
Flexible Material Sourcing Options
- Customer-Supplied Materials: Provide your own active materials, passive components, separators, or electrolytes
- Versatile Material Formats: Active materials can be supplied as raw powders, pre-mixed slurries, or pre-fabricated electrode sheets
- In-House Material Selection: Choose from NEI’s extensive selection of high-performance cathode and anode materials, solid electrolytes, and specialty components
Custom Electrode Fabrication
- Component Supply Options: Provide active materials, conductive carbon, binder systems, or pre-formulated slurries
- Slurry Preparation: Aqueous and non-aqueous slurry mixing, viscosity adjustment, and particle dispersion optimization
- Custom Specifications: Custom target electrode composition, active mass loading (mg/cm²), and calendered thickness
- Coating, Drying & Calendering: Slurry coating, temperature-controlled drying, thickness calendering, and electrode disc punching
- Standalone Electrode Delivery: Custom electrode sheets and discs can be shipped globally for internal evaluation or integrated directly into NEI’s coin or pouch cell assemblies
Coin Cell Configurations
- Standard Formats: CR2025 & CR2032 Coin Cell Assembly
- Cell Architectures: Half-cell (Li or Na metal counter electrode) and balanced full-cell configurations
- Controlled Environment: Assembly conducted in inert glovebox atmospheres with ultra-low moisture and oxygen levels
- Diverse Chemistries: Lithium-ion, Sodium-ion, Li & Na metal, Lithium-Sulfur, Solid-State, Aqueous systems, and Supercapacitors
Electrolyte & Component Integration
- Specialty Component Incorporation: Assembly of coin cells utilizing novel liquid electrolytes, gel polymers, solid-state electrolytes, and functional separators
- Electrolyte Modification & Additives: Custom electrolyte blending to mitigate gassing, prevent SEI breakdown, and suppress unwanted side reactions
- Custom Formulations: Electrolyte preparation tailored to your exact chemical specifications and testing requirements
Flexible Logistics & Delivery
- Direct Customer Delivery: Assembled coin cells safely packaged and shipped directly to your facility in North America
- Third-Party Delivery: Direct dispatch to designated external research or testing facilities
- In-House Testing Transfer: Seamless transfer into NEI’s cell testing program for immediate electrochemical evaluation
Pouch Cell Fabrication Services
Transitioning from small scale coin cells to prototype pouch cells is a critical milestone for demonstrating commercial viability. NEI offers custom pouch cell fabrication ranging from 0.1 Ah to 4 Ah capacity, accommodating diverse material sets and configurations to meet your R&D objectives and bridge the gap between active material synthesis and battery engineering.
Flexible Material Sourcing Options
- Customer-Supplied Materials: Provide your own active materials, passive components, separators, or custom liquid/gel electrolytes
- Material Formats: Active materials can be supplied as raw powders, pre-mixed slurries, or pre-fabricated electrode sheets
- In-House Material Selection: Choose from NEI’s inventory of cathode and anode materials, specialty components, and solid electrolytes
Custom Electrode Fabrication for Pouch Cells
- Component Supply Options: Supply active materials, conductive carbon, binder systems, or pre-formulated slurries
- Custom Specifications: Specify your target formulation ratios, active mass loading (mg/cm²), and calendered coating thickness
- Single & Double-Sided Coating: Electrode sheet coating with uncoated current collector margins suitable for tab welding
- Custom & Standard Formats: Fabricated with custom or standard matching counter-electrode pairings, high areal loadings, and precise coated widths
- Standalone Electrode Delivery: Custom electrode sheets can be shipped globally or integrated directly into NEI pouch cell builds
Pouch Cell Configurations & Capacities
- Cell Capacity Range: Custom cell builds from 0.1 Ah up to 4 Ah
- Electrode Footprint Sizes: Flexible sheet dimensions starting from 5 cm × 5 cm up to 11.6 cm × 7.6 cm
- Assembly Architectures: Single-layer, Z-stack multilayer, and jelly-roll configurations
- Cell Types: Half-cell (Li or Na metal counter electrode) and balanced full-cell assemblies
- Chemistry Options: Lithium-ion, Sodium-ion, Li & Na metal, Lithium-Sulfur, Solid-State, and custom systems
Semi-Automated Pilot-Scale Processing
- Pilot Equipment Capability: Larger project runs utilize semi-automated pilot-scale equipment for roll-to-roll tape casting, continuous calendering, and Z-stacking
- Process Compatibility: Verifies that novel materials or inactive components are compatible with standard battery manufacturing processes
- Prototyping Scalability: Accommodates larger sample quantities and multi-cell prototype build runs
Electrolyte & Component Integration
- Specialty Component Incorporation: Assembly of pouch cells utilizing novel liquid electrolytes, gel polymers, solid-state electrolytes, and functional separators
- Gassing & Side-Reaction Mitigation: Custom electrolyte blending and additive incorporation to mitigate gassing, prevent SEI breakdown, and suppress unwanted side reactions
- Custom Formulations: Electrolyte formulations mixed to customer-specified chemical ratios
Formation Cycling & Verification
- Cell Baseline Verification: Prescribed initial formation cycling to ensure proper SEI formation and cell operation
- Diagnostic Screening: Initial DCIR measurements, voltage monitoring, and electrochemical impedance spectroscopy (EIS)
- Data Reporting: Collected formation data and initial cell metrics delivered in a clean summary report
Delivery & Logistics Options
- Direct Customer Delivery: Fabricated pouch cells packaged and shipped directly to your facility, available with or without electrolyte (subject to shipping regulations)
- Third-Party Delivery: Direct dispatch to designated external research or testing laboratories
- In-House Testing Transfer: Direct transfer into NEI’s pouch cell testing and characterization program
Cell-Level Testing Services
NEI offers a robust suite of electrochemical testing and analytical characterization services for both coin cells and pouch cells. Whether evaluating cells fabricated in our facilities or analyzing customer-supplied test cells, our testing capabilities provide actionable insights into material kinetics, cycle life, thermal stability, degradation mechanisms, and overall cell quality.
Cell Cycling & Rate Capability
- Capacity & Life-Cycle Tracking: Long-term capacity retention, cycle life evaluation, and material-level specific capacity measurements
- Rate Performance: C-rate capability testing under varied charge and discharge current densities
- Internal Resistance & Power Metrics: Direct current internal resistance (DCIR) tracking, Hybrid Pulse Power Characterization (HPPC), and cell-level energy and power density evaluations
Wide-Temperature Cycling
- Thermal Range Testing: Controlled environmental chamber testing across broad temperature ranges (-40 °C to > 90 °C)
- Thermal Performance Profiling: Evaluation of capacity retention, rate capability, and impedance behavior under extreme temperature conditions
Electrochemical Impedance Spectroscopy (EIS)
- In-Situ Impedance Profiling: Frequency-response analysis to decouple internal cell resistance components
- Interfacial Diagnostics: Separation of ohmic resistance, charge-transfer resistance, and solid electrolyte interphase (SEI) growth over cycling
Cyclic Voltammetry (CV)
- Redox Characterization: Detailed identification of redox couples, phase transitions, and irreversible side reactions
- Stability Windows: Determination of electrochemical stability limits for novel active materials, coatings, and electrolyte formulations
Transport & Kinetic Measurements
- Electrolyte Conductivity: Temperature-dependent ionic conductivity profiling for liquid, gel polymer, and solid-state electrolytes
- Kinetic Transport Metrics: Lithium/sodium transference number determination and electronic/ionic electrode resistance analysis
Post-Mortem & Failure Analysis
- Controlled Cell Disassembly: Post-test teardown of cycled coin or pouch cells in an inert glovebox atmosphere to evaluate physical degradation
- Interfacial & Structural Inspection: Visual inspection and SEM/EDS imaging of harvested electrodes, separators, and interphases to determine failure mechanisms, lithium/sodium plating, and structural breakdown
Sample Requirements & Flexible Workflows
- Accepted Cell Formats: Testing services available for NEI-fabricated cells or customer-supplied coin cells (CR2032/CR2025) and pouch cells
- Custom Test Protocols: Flexible test profiles tailored to customer-specified voltage limits, temperature steps, and C-rate schedules
- Comprehensive Data Delivery: Raw cycling data, EIS Nyquist/Bode plots, CV curves, and summarized performance metrics delivered upon test completion
NEI’s Areas of Expertise
NEI Corporation’s cell fabrication and testing expertise spans a broad spectrum of energy storage chemistries, cell architectures, and component R&D across both coin cell and pouch cell form factors.
Lithium-ion & Lithium Metal Chemistries
- Cell Formats: Coin cells (CR2032, CR2025) and pouch cells (0.1 Ah to 4 Ah) in half-cell or full-cell configurations
- Li-ion Cathodes: NMC, LFP, NCA, LMNO, high-entropy oxides, and custom high-voltage oxide formulations
- Li-ion Anodes: Graphite, silicon/SiOx composites, LTO, hard carbon, and novel anode materials
- Lithium Metal Anodes: Bare, surface-passivated, or coated metallic lithium foils
Sodium-ion & Sodium Metal Chemistries
- Na-ion Configurations: Half cells and full cells in coin and pouch formats
- Na-ion Cathodes: Layered transition metal oxides (e.g., Na0.44MnO2), Prussian blue analogues, and polyanion compounds
- Na-ion Anodes: Hard carbon, alloy-based anodes, and metallic sodium
Next-Generation Systems & Specialty Chemistries
- Solid-State & Gel Polymer Electrolytes: Sulfide, oxide, and polymer matrix solid electrolytes
- Ionic Liquid & Organic Systems: Ionic liquid formulations and novel organic electrolyte systems
- Aqueous Battery Systems: Water-in-salt electrolytes, aqueous sodium-ion, and other cation formulations
- Lithium-Sulfur (Li-S): Lithium-sulfur cell fabrication and evaluation
- Supercapacitors: Organic and aqueous supercapacitor systems
- Multivalent & Alternative Chemistries: Magnesium, zinc, lead, iron, or hydrogen systems
Cell Component & Inactive Material Evaluation
- Separators: Standard polyolefin, glass fiber, ceramic-coated, and functional separators
- Conductive Additives: Carbon black, carbon nanotubes (CNTs), graphene dispersions, and conductive graphite
- Binders: Standard (PVDF, aqueous CMC/SBR) and novel aqueous or fluorinated binder systems
- Current Collectors: Aluminum, copper, carbon-coated foils, and porous conductive substrates (e.g., carbon paper)
Related Battery Services
NEI offers complementary material synthesis, particle modification, and structural characterization services to support your broader R&D workflow. Explore our additional capabilities:
Custom Material Synthesis & Scale-Up
- Synthesis & Scale-Up: Bench-scale to pilot-scale synthesis of custom anode and cathode powders, high-entropy oxides, solid electrolytes, and surface-engineered particles
- Custom Formulations: Batch production tailored to customer-specified chemical compositions, stoichiometry, and particle morphology
Surface Modification & Particle Coating
- Particle Passivation: Nanoscale surface coatings and protective passivation layers applied directly to active powders prior to slurry mixing
- Performance Optimization: Engineered surface treatments designed to mitigate unwanted side reactions, reduce gassing, and enhance overall cycle life
Physical, Structural & Chemical Powder Characterization
- Residual Lithium Analysis: Quantitative measurement of free lithium carbonate (Li2CO3) and lithium hydroxide (LiOH) surface content in cathode active powders
- Composition & Morphology: Powder X-ray Diffraction (XRD) for phase identification, Optical Microscopy, and Scanning Electron Microscopy with Energy Dispersive Spectroscopy (SEM/EDS)
- Physical & Density Analytics: Tap density testing, Particle Size Distribution (PSD), BET surface area analysis, and helium pycnometry
- Spectroscopic & Thermal Characterization: UV-Vis Spectroscopy (190 nm to 1100 nm), Fourier-Transform Infrared Spectroscopy (FTIR), Thermogravimetric Analysis (TGA), and Differential Scanning Calorimetry (DSC)
Request a Quote & Technical Consultation
Ready to get started on your custom cell fabrication or testing project?
Whether you need a batch of coin cells assembled with proprietary material, custom pouch cell prototyping, or a comprehensive cell testing program, NEI’s technical team is ready to assist. Your Intellectual Property is fully protected at all times (view & download our NDA).
How to Proceed:
- Submit Your Project Details: Complete the inquiry form below with information regarding your material(s) and testing requirements.
- Technical Review: One of our battery materials specialists will review your specifications and follow up to discuss formulation details or test protocols.
- Receive a Customized Proposal: We will provide a tailored quote and estimated turnaround schedule for your project.
Updated October 2, 2026