Patented DBE Technology
First-mover advantage with protected dry electrode systems (Patent US12136727B2)
Markets
BatteryPrecision-engineered systems for energy storage breakthroughs — from lab-scale testing to gigafactory-scale deployment
Empowering Battery Manufaturing
Architects of industrial excellence
From electrodes to separator films — we develop precision systems for battery component production.
We deliver high-precision, scalable systems that span the entire battery component production value chain. From initial material assessment and process design to full-scale equipment deployment, commissioning, and continuous optimization, our approach combines engineering excellence with deep domain expertise — ensuring superior performance from R&D to mass production.
Material Science & Chemistry
We develop and refine custom chemistries – from electrode powders and binders to functional primer layers – optimized for compatibility with both wet and dry coating processes. Our labs support slurry formulation, solvent-free processing, and material characterization, ensuring consistency, performance, and compliance.
Manufacturing Process Concept
Our process engineering experts design tailored manufacturing workflows – including DBE-specific configurations – with simulation-based validation and performance modeling. We define optimal coating, drying, calendering, and lamination setups to support high-efficiency, high-throughput production.
Process Optimization & Service
We offer inline diagnostics, AI-driven metrology integration, and predictive maintenance strategies to maximize uptime and yield. Our continuous support includes remote diagnostics, process tuning, and global field service to adapt lines to new chemistries or performance targets.
Battery Electrodes
We provide complete electrode production systems for both wet-coated and dry-processed formats. Our multi-roll calenders and slot-die coating lines ensure precise control of thickness, porosity, and density — essential for energy-dense, stable battery performance.
Battery Separator Film
Our separator film coating lines are engineered for tension-sensitive microporous substrates. Featuring non-contact drying, advanced web handling, and dual-side coating in a single pass, they ensure uniform ceramic or functional coatings at production speeds up to 200 m/min.
Equipment Deployment
From lab-scale test rigs to full gigafactory installations, we manage all stages of deployment — including pre-assembly, factory and field acceptance testing (FAT/SAT), and operator training. Every system is designed for seamless integration, long-term operability, and global support.
Proven innovation. Patented performance. Ready to scale.
Dry Battery Electrode (DBE) Production
As the first mover in Dry Battery Electrode (DBE) manufacturing, Matthews Engineering delivers patented, production-ready systems that redefine electrode fabrication.
Our DBE technology eliminates toxic solvents and drying ovens, enabling a cleaner, faster, and more cost-effective process. Integrated with precision multi-roll calenders, inline metrology, intelligent primer coating, and full material handling automation, our DBE lines are built for maximum energy density, manufacturing efficiency, and scalability.
Explore our full range of DBE production solutions to see how we help battery innovators move from lab to gigafactory — with confidence.
Multi-Roll-Calender
Designed for dry electrode processing in low-volume production lines, this multi-roll calender ensures uniform densification without solvents. Its compact, modular layout is ideal for pilot-scale runs or early-phase commercialization.
Optimized chemistries. Engineered for industrial performance.
Material Science & Conductive Powder
Material science is a cornerstone of our innovation strategy. Our expertise spans the formulation and processing of conductive powders, binders, and slurries tailored to both dry and wet battery electrode manufacturing.
Through in-house R&D and pilot testing, we optimize material behavior under calendaring, coating, and drying conditions – ensuring uniform dispersion, improved conductivity, and long-term electrochemical stability.
Whether you’re evaluating new active materials, transitioning to solvent-free DBE processes, or scaling a next-gen formulation, we provide deep application insight, precise process compatibility, and a clear path to manufacturability.
High-precision systems for continuous and intermittent electrode production
Wet Coating Process Expertise
Our wet coating lines support both continuous and intermittent electrode production with precision slot-die technology, advanced drying systems, and tight web tension control. Ideal for current lithium-ion battery manufacturing, our systems deliver uniform coatings, high throughput, and easy integration with upstream and downstream processes.
Explore our calender systems for reliable, scalable electrode manufacturing that meets today’s quality and productivity standards.
Calender for Continuous Coated Battery Electrodes
High-speed, precision calendering for roll-to-roll coated electrodes - ensuring uniform thickness, density, and mechanical integrity in large-scale lithium-ion production.
Calender for Intermittent Coated Battery Electrodes
Designed for intermittent patterns and pulse-coating lines, this calender ensures stable compaction and smooth transitions between coated and uncoated web sections.
Engineered for precision — built for delicate microporous substrates.
Battery Separator Film Coating
Our separator film coating systems are purpose-built for the challenges of high-performance lithium-ion batteries. With gravure coating accuracy, ultra-sensitive web handling, and non-contact drying technologies, our solutions enable uniform functional coatings on microporous PE and PP films.
Designed to operate at low web tension and high line speeds, these lines ensure flawless double-sided coating in a single pass — minimizing material waste and maximizing throughput.
Discover our Separator film coating solutions and see how we help you meet the highest standards in safety, stability, and energy efficiency.
Coating Lines for Battery Separator Film
Our coating systems enable ultra-thin, uniform coatings on separator films used in lithium-ion batteries - with integrated tension control, low-solvent operation, and inline inspection capabilities.
Where innovation moves from concept to production
Our Development Center is the cornerstone of industrial battery innovation. Located in Vreden, Germany, this state-of-the-art facility spans over 1,000 m² and combines simulation environments, flexible pilot-scale test bays, and a maker workshop for rapid prototyping. Designed to bridge the gap between lab and large-scale manufacturing, it enables fast, reliable process validation — including for next-generation DBE and wet electrode technologies.
Equipped with our modular GK300L laboratory calender, the Development Center offers unmatched versatility for laminating, embossing, coating, and compressing. Whether you’re refining a primer coating, testing a dry film formulation, or simulating full electrode processes, the GK300L provides precise, scalable insights into real-world manufacturing performance.
From proof-of-concept to pilot-scale feasibility, our customers gain direct access to:
Material behavior testing under industrial conditions
Replicate full-scale process conditions using original substrates, powders, binders, and coatings. Evaluate deformation, compression, tension response, and thermal interactions on web materials under real-world calendaring, drying, or coating stress scenarios.
Pilot line simulations for DBE and wet processes
Run scalable test campaigns for both dry and slurry-based electrode production. Use modular pilot setups — including slot-die coating, floatation drying, multi-roll calendering, and lamination units — to simulate full electrode processing steps, from primer coating to final densification.
Drying Room Technology
Test and refine processes in dedicated dry room environments equipped with controlled humidity and particulate filtration systems. Ideal for sensitive materials such as DBE powders and electrolyte-coated films, our drying zones maintain <1% RH and are configured for solvent-free, cleanroom-ready production simulations — ensuring process stability and material integrity from lab to line.
Custom process development with expert engineering guidance
Collaborate directly with our chemical, mechanical, and automation engineers to co-develop process flows, equipment settings, and quality parameters tailored to your material system and application — including inline gap control, tension mapping, and powder flow validation.
Process scalability mapping for confident production deployment
Validate lab results against industrial benchmarks with seamless parameter transfer to full-scale systems. Compare pilot outcomes with expected production speeds, coating loads, and gap tolerances to de-risk your scale-up and reduce commissioning timelines.
Explore our lab-scale systems designed to replicate industrial conditions — empowering you to validate safety, enhance material stability, and optimize energy efficiency from the start.
Laboratory Calender GK 300 L for battery electrodes
Compact, configurable calendering unit for R&D and pilot-scale applications - perfect for material testing, parameter optimization, and pre-production validation.
Laboratory Calender GK 300 L 6R for battery electrodes
A high-precision, six-roller calender system designed for R&D and small-batch production. Ideal for material validation, parameter optimization, and pilot-scale trials - offering full control over compaction, temperature, and web handling in a compact footprint.
Development Center
Test, validate, and refine your materials and processes in our dedicated development center - equipped for trials, scale-up, and next-gen prototyping.
Calender Rollers
Built for precision. Proven in battery manufacturing.
Engineered for demanding battery applications, our calender rollers ensure uniform web compression, stable surface finish, and high material integrity. Designed for thermal stability and consistent line force, they support the precise electrode structure required for next-generation lithium-ion performance. Ideal for both new system integration and retrofitting, our rollers are a reliable foundation for scalable, high-efficiency production environments.
Our refurbishment services restore worn calender rollers to full functionality, extending lifespan, maintaining precision, and reducing total cost of ownership — for sustainable performance and long-term value.
Technology you can trust. Expertise you can scale.
Our patented DBE technology, full-spectrum process know-how, and rapid scalability make us the preferred partner for innovators in battery manufacturing. Whether you're scaling lithium-ion lines or preparing for next-gen chemistries, our modular systems and global service network ensure you're equipped to lead — with precision, speed, and long-term reliability.
Full Process Expertise
From powder preparation to electrode finishing, we cover the entire value chain
Scalability at Speed
Rapid transfer from lab to industrial production through our MEODEO demo line
Modular & Configurable Systems
Tailored to evolving battery chemistries and performance needs
Global Service & Engineering Network
Local support, global reach, 70+ years of industry expertise