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Area Tab Guide System
Project Type
Mechanical Design & Manufacturing
Client
Ultium Cells, LLC (UC1 Factory)
Timeline
August 2025 – November 2025
Status
Completed; 26 units deployed and operational in Notching and Drying Section of the Factory (Anode & Cathode Side).
Roles and Responsibilities
1. Solely led the end-to-end design and development of the Area Tab Guide System redesign project — from concept ideation to final installation across 26 production lines.
2. Conducted root cause analysis of the tab deformation issue and developed seven unique design concepts using SolidWorks, addressing functional and manufacturability constraints.
3. Prepared and presented design concepts to the customer engineering team, incorporated feedback, and finalized three candidate designs for prototype evaluation.
4. Utilized SolidWorks CAM to generate machining toolpaths, G-codes and personally manufactured prototype sets using a 3-axis CNC milling process.
5. Performed structural and deformation simulations in ANSYS to validate redesigned geometries prior to prototype trials.
6. Led on-site installation of prototype sets and collaborated closely with customer engineers during testing and validation phases.
7. Finalized the optimal design configuration that eliminated tab deformation while maintaining full compatibility with the existing system.
8. Personally, manufactured all 26 production sets, ensuring high precision, consistency, and timely completion within the 3-month project window.
9. Prepared detailed engineering documentation, including BOMs, design phase records, and installation reports, for prototype and production stages.
10. Demonstrated strong technical ownership, initiative, and commitment under urgent production conditions, often working extended hours and weekends to ensure immediate resolution.
Technologies Used
1. Design: SolidWorks
2. CAM: SolidWorks CAM
3. Manufacturing: Haas TM-2P (3-axis CNC Milling Machine)
4. Material: 6061 Aluminum
5. Testing: ANSYS (structural and deformation analysis), prototype validation of three design ideations conducted on production lines.
Key Highlights
- Resolved a critical tab deformation issue in high-speed EV battery manufacturing equipment.
- Designed, manufactured, and implemented 26 optimized guide systems within 3 months (August–November).
- Developed seven concept designs; three prototypes tested, and one finalized with zero deformation.
- Led complete workflow — design, CAM, CNC manufacturing, documentation, and installation.
- Improved production stability and eliminated tab crushing incidents.
The Area Tab Guide System is an integral component used in the Notching and Drying machines of EV battery manufacturing, responsible for monitoring the area consistency of electrode tabs immediately after laser notching. Operating at high speeds (~800 rpm), the system uses a high-speed camera and backlight arrangement to capture precise tab images as cathode (aluminum) and anode (copper) sheets pass through the top and bottom guide structures. The original guide design caused severe tab deformation due to collision between the thin electrode tabs and the top guide surface, leading to crushed tabs and frequent production disruptions. To address this critical issue, I led the redesign of the top tab guide geometry under tight time constraints, developing seven design concepts in SolidWorks. After review with the customer, three prototype sets were manufactured via CNC and tested in actual production lines. The final selected design fully eliminated deformation while maintaining compatibility with the existing assembly. The optimized guide system was manufactured and installed across 26 production lines, successfully resolving the issue within three months (August–November) and restoring stable production performance.
