ALF-Case Pouch Cell Case with Customized Size

ALF-Case is a pre-formed pouch cell case manufactured from aluminium laminated film (ALF), designed to package lithium-ion polymer and soft-pack pouch cells for laboratory prototyping and pilot-scale R&D. The case is created by thermo-forming ALF using a precision die, producing a defined cavity (“pit”) to house stacked electrodes, separator, and electrolyte before heat sealing.

How it works (forming mechanism)

A forming mould shapes the aluminium-laminated composite under controlled pressure (and typically heating) to create a consistent pocket depth and geometry. Researchers can then insert the electrode stack, add electrolyte, and complete top/side sealing with standard pouch cell sealing equipment. This workflow supports repeatable cell builds for electrochemistry and battery testing studies.

Key options and available die sizes

Pit configuration

• Single pit: one cavity per formed sheet
• Double pit: two cavities per formed sheet
  
  

Existing die models (mm)
Single pit: 34×50, 41×76, 57×101, 43.5×121, 75×90, 91×101, 147.5×235, 67×90
Double pit: 17×24, 41×75, 42×75, 42×77, 51×77, 52×77, 56×81, 101×210, 128×137

Pocket depth / thickness guidance

• Max thickness is stated as ~2.8 mm for single-pit designs, with thickness adjustability noted up to ~5.5 mm (design-dependent).
  
  

Compatibility and typical applications

• Compatible with pouch-cell R&D workflows (stacking, electrolyte filling, vacuum sealing, formation cycling).
• Used for lithium-ion pouch prototypes, materials screening, formation studies, cycling/ageing, and in-house electrochemistry validation (pair with potentiostats, battery cyclers, and temperature-controlled test fixtures).
  
  

Why source through ScienceGears

We supply pouch cell consumables and can help you choose the right cavity size, pit style, and depth for your electrode stack thickness, separator choice, and sealing method—supporting faster, more repeatable pouch-cell builds in Australia and New Zealand.