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Advanced Laser Converting & Battery Foil Processing Machines

Manufactured in Devon, England — Trusted Globally Across High-Tech Sectors

The Hanbury-Autogil custom-designed laser converting machines are engineered to process a wide range of thin metals, battery foils, and sensitive substrates for next-generation applications in the EV battery, aerospace, pharmaceutical, and industrial sectors.

Our systems are used worldwide to support precision manufacturing where tight tolerances, ultra-clean processing environments, and material-specific performance are critical.

Engineered for Innovation in Energy and Electronics

We support cutting-edge applications in the rapidly evolving electromobility and advanced materials sectors, including:

  • Electric Vehicle Battery Cells & Modules

  • Battery Pouches, Anode & Cathode Foils

  • Lithium-Ion (Li-ion) and Li-Sulfur Battery Production

  • NiMH and Na-NiCl₂ (Zebra) Battery Processing

  • Automatic Cylindrical & Prismatic Cell Assembly

  • Battery Electric Vehicle (BEV) Component Manufacturing

  • Marine & Industrial Battery Applications

Our custom machinery ensures accurate laser cutting, registration, stacking, and integration — essential for the performance and safety of modern battery systems.

Laser Precision, Built-In Intelligence

Hanbury-Autogil’s special-purpose laser systems combine high-precision cutting with modular automation and real-time process control, enabling:

  • Micron-level Laser Cutting & Ablation

  • Thin Metal Foil Converting (e.g. copper, aluminium, rare metals)

  • Cleanroom-Compatible Construction

  • Vision Inspection & Registration Mark Detection

  • Inline Slitting, Stacking & Lamination

  • Reel-to-Reel & Sheet-Based Processing Options

  • High-Speed Waste Matrix Removal & Fume Extraction

All systems are tailored to your substrate characteristics, thermal tolerances, and production throughput targets.

Industries We Serve

Our laser converting systems are used in a wide range of high-spec sectors:

  • Electric Vehicle & Battery Manufacturing

  • Aerospace & Automotive

  • Advanced Electronics

  • Medical Devices & Diagnostics

  • Consumer Electronics

  • Energy Storage Solutions

  • Defense & Marine Technologies

Your Partner in Technical Precision

With over 50 years of machine-building experience and in-house R&D, Hanbury-Autogil leads in providing turnkey converting systems for modern materials and future-ready manufacturing.

From battery innovation to advanced laser converting, our machines are engineered to give you an edge in precision, productivity, and scalability.

Processing Fire Barrier Components for EV Battery Safety

With increasing emphasis on thermal management and safety in electric vehicle battery systems, Hanbury-Autogil provides converting solutions specifically tailored for EV battery fire barrier components.

Our machinery can process advanced fire-retardant and thermal insulation materials, essential for:

  • Battery module and pack-level thermal barriers

  • Cell-to-cell fire propagation prevention layers

  • Intumescent tapes and mica-based composites

  • High-temperature dielectric separators

  • Thermal runaway containment liners

Using precision laser cutting, kiss-cutting, and lamination techniques, we enable accurate processing of multilayered fire-resistant materials — such as ceramic-impregnated foams, non-woven aramid fibres, mica laminates, and specialty polymer films.

These components are critical to meeting stringent UN 38.3, UL 94, and OEM-specific thermal protection standards in BEV, PHEV, and marine EV battery systems.

Hanbury-Autogil’s converting systems offer:

  • Clean, sealed-edge cutting to prevent delamination

  • Automated stacking and positioning for multilayer barrier assembly

  • Vision-guided placement for precision alignment in safety-critical zones

  • High-output converting with minimal material stress or distortion

Battery Electric Vehicle (BEV) Cell Types

Pouch Cell is geometrically beneficial as it is easy to scale in size. The battery industry also know this cell as the ‘coffee bag cell’

Prismatic Cell consists of stacked anode and cathode cell packs. This method delivers space saving benefits. Manufacturing is more complex but this method provides perfect energy density maximizing battery life.

Cylindrical Cell is best described as a more classic battery shape. Type 21700 is normally used in EV automotive batteries.

 

Modular Laser Machines

Many years of expert machine building, Hanbury Autogil brings a dynamic modular approach to machine building. With many roll-to-sheet solutions, taking material from a roll, converting, cutting and automatically transitioning to the next stage of manufacturing.

Each Converting Machine project is managed by a specialist team at Hanbury-Autogil with all elements controlled internally. Hanbury-Autogil uses solid works software for planning and has an internal electrical and mechanical design team. Machine parts are designed and machined internally in our dedicated precision engineering facility.

Collaboration

The converting process of many types of material can have multiple stages. Each stage from material presentation – coil or sheet, cut, preparation, print, waste, extraction, stack, recoil and package can be automated by a Hanbury-Autogil converting machine. We work with you to solve any problems and provide total material converting solutions.

Hanbury-Autogil 60+ Years Experience

With a Hanbury-Autogil foam converting machine you can increase production, enhance quality and reduce maintenance. We work with customers around the globe and in various industries to deliver bespoke cutting edge converting machines.

Customers around the Globe