Set us a challenge and watch us go

Process Engineering

This service is for you if your material can’t be processed with existing equipment. Maybe you’ve got a wacky idea and want to get this slurry into a 3D substrate, or this coating onto that separator — but you’ve got no idea how to do it. We can help.  

We aren’t limited by what’s already possible.

If you ask us to work with new materials or build a cell that’s never been built before, we won’t brush you off with a “Nope, sorry, not in our wheelhouse.” We’ll roll up our sleeves, sharpen our pencils, and find a way to do it

We’ve evolved some pretty impressive process engineering capabilities over the years. Most of them are directed at coating, cell development, process controls and materials characterization. And they all lead to what we like to call: artisanal batteries.

So don’t just think of us as battery nerds. We’re also creative inventors who can guide you through uncharted territory on a route that’s all your own.

Here’s an example of a Process Engineering project:

  1. We identify the problem

    You want to make an offbeat cell, but it’s very hard to do and you don’t know where to start. It also requires equipment or process that we don’t have… yet.

  2. We identify the solution

    We outline your options by identifying the equipment or process you’ll need and the process for constructing the cells

  3. We get to work

    We build the solution in our lab and then develop the process that will get your cells made and ready to roll.

  4. We produce results

    We build, say, pouch cells for you and then put them through the appropriate tests.

  5. We share, you learn

    We open up our lab to you for the entirety of the project. You visit us to see exactly what we’re doing. Plus, we train you to use the new equipment and process.

  6. We get to work

    At the end, we either send you the equipment (with instructions), or help you buy your own. We can also be onsite during setup and troubleshoot as necessary.

Want to see our process engineers in action?

Success stories

Science is nothing without proof.
So here are some testimonials from our customers.

“Their team has shown a deep knowledge of the battery market and technical knowledge. We really appreciated the practical knowledge Polaris brings… It goes beyond academics. Their team-based approach also brings numerous perspectives and offers unique and creative ideas to develop new solutions and solve problems. They were always highly responsive with timely feedback to questions and requests and possessed a good balance of attention to detail with the ability to move quickly towards commercialization.”

– Tier 1 Material Developer

“These guys have been great! Fast, economical, and extraordinarily helpful. I can recommend them wholeheartedly.”

– Jeff Arias, Sienza Energy

“Doug and the Polaris team have deep technical expertise and experience in electrode processing and cell fabrication that they use to help their clients rapidly advance their businesses. They also work tirelessly to support their clients in a responsive, professional way. Polaris helped Natron Energy develop our first pilot-scale electrode manufacturing processes so that we could rapidly grow its business and take our first product into production. We look forward to working with Polaris again.”

– Colin Wessells, CEO, Natron Energy

“As we were exploring the viability and potential benefits associated with our new Li-ion related technology, we greatly appreciated the technical depth, collaboration and rapid prototyping/testing capability that the Polaris Team contributed to our efforts.”

– Eric Gaver, New Business Development, GORE

Let us be your guides:

Talk to us about Process Engineering

Whether you know exactly what you need, or you’ve never done this before, we’ll plot your route to commercialization.