Scaling Battery Manufacturing: Best Practices for High-Efficiency Gigafactories

The term "gigafactory," originally coined by Tesla CEO Elon Musk, has become synonymous with large-scale battery manufacturing facilities. The "giga" prefix not only reflects the massive scale of these factories but also alludes to the gigawatt hours of storage capacity they produce.

The increasing popularity and availability of electric vehicles (EVs), coupled with improved performance, diverse vehicle offerings, and a growing market for stationary energy storage solutions (such as onsite backup batteries or renewable storage), has driven a surge in battery production over the past five years. As a result, the architecture, engineering, and construction (AEC) industry has been flooded with opportunities to design and build these complex facilities.

In this article, we explore the role of gigafactories in modern battery production and outline the integrated coordination efforts that enable a seamless, full-service approach to their planning and execution.

What Makes a Gigafactory Different?

Unlike traditional battery manufacturing plants that may focus on a single component of the process, gigafactories streamline production by handling everything from raw material processing to final battery pack assembly under one roof. This level of vertical integration reduces logistical challenges, optimizes material flow, and scales production—while vastly increasing the complexity of the building.

A key function of gigafactories is managing raw material processing on-site. Essential battery materials such as lithium, nickel, cobalt, and graphite undergo refinement and preparation, reducing logistics costs and supply chain disruptions. Once processed, these materials are used in cell manufacturing, which involves electrode production, electrolyte filling, and formation cycles.

After individual cells are manufactured, they are assembled into battery modules or packs. Comprehensive quality assurance processes, including X-ray and ultrasonic scanning, detect defects, while high-stress cycle testing ensures reliability. Gigafactories also include on-site research and development (R&D) labs, where manufacturers test new chemistries, improve production efficiency, and drive technological advancements. Supporting all of these functions are administrative areas, logistics hubs, and employee facilities that require a different design approach than production spaces. Given the sheer number of functions under one roof (or on one site under multiple buildings), gigafactories present significant technical and logistical challenges.

As of 2025, there are approximately 240 gigafactories worldwide, with projections estimating more than 400 by 2030. This rapid expansion, driven by the rising demand for EVs and battery storage solutions in renewable energy applications, has led to the Midwest region of the U.S. being nicknamed the "Battery Belt."

The Functional Zones That Make Up a Gigafactory

Gigafactories are highly specialized manufacturing environments with multiple functional zones, each with specific design and engineering requirements.

• Raw Material Processing Areas handle material refinement, electrode coating, and chemical mixing. These spaces require contamination controls and often utilize automated storage and retrieval systems (AS/RS) for efficient material handling.

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• ‍Cell Manufacturing Areas involve intricate processes such as electrode production, cell stacking or winding, electrolyte filling, and initial charging. Since moisture exposure can degrade battery performance and safety, these spaces require ultra-dry rooms with extremely low humidity levels—reaching dew points as low as -60°C. Robotic automation ensures precision and reduces human error in handling sensitive materials. Additionally, cell production requires strict temperature controls, advanced filtration, and differential pressure relationships for contamination prevention.

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• ‍Module and Pack Assembly Areas integrate individual cells into battery modules and packs, incorporating robust thermal management to prevent overheating and ensure optimal performance. Fire suppression and other safety protocols mitigate risks like thermal runaway.

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• ‍Quality Control and Testing Facilities employ X-ray and ultrasonic scanning to detect defects, while high-stress cycle testing verifies battery reliability under extreme conditions.

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• ‍Research and Development (R&D) Labs support battery innovation. These flexible, experimental production spaces allow engineers and scientists to test new materials and manufacturing processes quickly.

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• ‍Administrative and Logistics Areas include command and control centers, offices, training facilities, and warehousing. Juxtaposing the sterile environment of the fabrication areas with thoughtfully designed administrative spaces ensures a cohesive and functional facility.

How A/E Firms Support High-Efficiency Gigafactory Design

The AEC industry plays a critical role in designing and constructing efficient gigafactories. Optimized facility planning ensures cost-effective operations while meeting the high-performance demands of modern battery production. Architectural-engineering (A-E) firms, particularly full-service firms offering all engineering disciplines in-house, are instrumental in balancing client needs with constructability requirements. Key coordination efforts in gigafactory design include:

• Architectural Considerations: Modular construction systems, such as insulated metal panels (IMP) for walls and ceilings, enhance thermal control and energy efficiency. Prefabrication and modular assembly allow for rapid construction, scalability, and reconfigurability. Efficient space planning, guided by LEAN principles, minimizes transportation distances between production areas, reducing inefficiencies. Ballroom-style layouts with minimal internal columns maximize flexibility for future automation, while high-bay construction supports vertical storage and AS/RS systems.

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• Mechanical Engineering Strategies: Environmental control, particularly in ultra-dry room technologies, is paramount. Dual-rotor desiccant dehumidifier systems provide enhanced humidity control, with supply air dew points as low as -80°C to prevent moisture contamination in lithium-ion battery manufacturing. Maintaining these dry rooms requires expertise in cascading pressure control relationships. Given the significant energy demands of these spaces, HVAC optimization and energy recovery strategies can reduce operational costs, often yielding payback within five years. Heat exchangers and energy recovery systems reclaim waste heat, while zoned climate control optimizes temperature and humidity conditions efficiently.

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• Electrical Engineering Innovations: Many gigafactories integrate on-site renewable energy solutions, such as solar photovoltaic (PV) panels and wind turbines, to supplement power needs. Battery energy storage systems (BESS), often using the same batteries produced in-house, allow for energy storage and optimized power usage. Smart grid and load management strategies further enhance efficiency. Medium-voltage distribution networks reduce power losses, and peak load shedding techniques help avoid high utility rates during peak demand periods.

Scaling battery manufacturing to meet the surging demand for EVs and energy storage solutions requires highly efficient gigafactory designs that integrate advanced architectural, mechanical, and electrical engineering principles. By leveraging modular construction, precision-controlled environments, energy-efficient systems, and on-site renewable energy generation, the AEC industry can support the development of sustainable, high-output gigafactories.

With over 400 gigafactories projected globally by 2030, continuous innovation in automation, energy management, and materials handling will be essential for maintaining cost-competitive and environmentally responsible battery production. As the industry evolves, A-E firms must collaborate closely with manufacturers to push the boundaries of efficiency and scalability in gigafactory design.

At Progressive Companies, our team of controlled environment technical experts specializes in bringing battery manufacturing facilities from vision to reality. With extensive experience in high-performance industrial environments, we provide end-to-end solutions that ensure efficiency, scalability, and sustainability. Whether you are planning a new gigafactory or optimizing an existing one, we have the expertise to make your project a success.

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Sources:

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Parliament UK — Business, Energy & Industrial Strategy Committee. (2023, November 21). Batteries for electric vehicle manufacturing. House of Commons. https://publications.parliament.uk/pa/cm5804/cmselect/cmbeis/196/report.html UK Parliament

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