0102030405
Stamped grid vs. extended grid: Optimizing lead-acid battery manufacturing cost and performance | MINHUA Group
2025-02-21
Technology Comparison Module (Infographic-friendly)
1. Core process principles
| scope | Expanded Grid | Stamped Grid |
|---|---|---|
| Material preparation | Lead melting → continuous casting (0.8-2.0mm strip) | Lead melting → continuous rolling (1.2-3.0mm strip) |
| Molding method | Punching + mechanical stretching (18-25m/min) | Precision stamping (300-500 times/minute) |
| Dimensional tolerance | ±0.2 mm | ±0.05mm (depending on the mold) |
| Key Equipment | Pipe Expanding Machine | Progressive Die Stamping Machine |
Main Differences：
- Stamped meshes rely on high-precision dies (±0.05mm) to achieve complex geometries; extended meshes prioritize flexibility but have lower accuracy.
2. Performance indicators
2.1 Mechanical strength (ASTM E8 standard)
| Test Parameters | Expanding the Grid | Stamping Grid |
|---|---|---|
| tensile strength | 38-42 MPa | 55-62 MPa |
| Elongation at break | 15-18％ | 8-12％ |
| Fatigue life (cycles) | 5,000 | 8,000+ |
Meets ASTM E8 standards：
- Gauge Length: 4D (E8) or 5D (E8M) for consistent specimen preparation.
- Strain rate: 0.015±0.006 mm/mm/min (closed-loop control).
2.2 Economic Benefits of Production (US$/10,000 units)
| Cost Category | Expanding the Grid | Stamping Grid |
|---|---|---|
| Mold cost | 0 | 700-1,200 |
| Energy costs | 120 | 180 |
| Waste Recycling | XXV | 85 |
| Total Cost | 145 | 965+ |
Key insights：
- Stamped grids incur 75% of tooling costs and are only suitable for large-scale production; expanded grids reduce scrap rates by 70% and are ideal for cost-sensitive projects.
Industry Application Guide
3. Recommended scenarios
| technology | application |
|---|---|
| Expanding the Grid | ✅ Automotive SLI batteries (>100,000 units per month) |
| ✅ Cost-sensitive ESS projects (capex reduction of 40%) | |
| ✅ Standardized grid design (diamond/rectangular pattern) | |
| Stamping Grid | ✅ Start-Stop/Deep Cycle Batteries (>1,200 cycles per IEC 61427) |
| ✅ Custom geometry (honeycomb/radial grid) | |
| ✅ High precision tolerance (thickness variation |
Scenario Analysis：
- Start-Stop System: The tensile strength (55-62 MPa) and fatigue life (8,000+ cycles) of the stamped grid can meet the needs of frequent charging and discharging.
- ESS Project: Total cost of scaling the grid ($145/10,000 units) is suitable for CapEx-sensitive deployments, and standardized design enables scalability.
Innovation Trends and References
- Advanced Mesh Geometry: Stamped grids increase active material loading by 18% through honeycomb structure, which has been verified in grid-formed ESS projects (such as Xinjiang Bayingol shared ESS).
- Mould Technology：Gree's ±0.001mm precision molds and 380 times/minute stamping speed are accelerating its application in high-end electric vehicle batteries.
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