One thing battery prototyping teaches you quickly: dust is not “just dust.”
A tiny particle can increase resistance, create defects, affect cycle life, or even trigger failure later.
Making one good cell is easy.
Keeping contaminants out consistently is the real challenge.
One thing I underestimated in battery prototyping:
tiny process inconsencies become huge performance differences later.
Even slight variation in pressure, drying, or alignment can cmpltly change results.
Lab-scale success is easy.
Repeatability is the hard part.
Do you agree?