Battery Technology: Solid-State Batteries & Sustainable Manufacturing
- venessa50
- Feb 28
- 6 min read
In this edition, featuring the Solid-State Batteries and Battery Materials Virtual Event in February 2025, we explore battery manufacturing and energy storage. Experts from Sakuu discuss how dry electrode printing and additive manufacturing are revolutionizing solid-state battery production, significantly reducing energy consumption and eliminating toxic materials. Fraunhofer IFAM presents sustainable screen-printing technology for lithium-ion electrodes, enhancing efficiency and scalability while minimizing solvent use. Sandia National Laboratories provides a multi-scale safety evaluation of sodium-ion batteries, analyzing thermal stability, degradation, and fire risk mitigation. P3 Automotive GmbH examines next-generation battery strategies for 2027+, including Cell-to-Pack (CTP) and Cell-to-Chassis (CTC) integration, sodium-ion alternatives, and diversified battery portfolios for automotive and energy storage applications. Lastly, Orion Carbons highlights the critical role of engineered carbon black in enhancing lithium-ion and solid-state battery performance.
Sakuu | Reinventing manufacturing for better batteries
Fraunhofer IFAM | Printing technology as green alternative for thick layer Li Ion Battery electrode production
Sandia National Laboratories | Multi-Scale Safety Evaluation of Commercial Sodium-ion Cells and Materials
P3 automotive GmbH | Next-gen battery strategies 2027+ | Potentials and challenges for future battery designs and diversification in product portfolios to serve a large bandwidth of market applications
Orion Carbons | Engineered Carbon Blacks for Energy Storage Applications
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1.Sakuu | Reinventing manufacturing for better batteries
Arwed Niestroj
For decades the manufacturing process of batteries and its components has shown only incremental improvements to cost efficiency, energy efficiency and low yield rates. It requires a significant technology step to harvest new efficiencies in capex, opex, sustainability and new battery storage solutions. Advances in battery material science combined with experience from the semiconductor manufacturing industry now enable significant progress in electrode manufacturing, new battery concepts, solid state batteries and safer energy storage.
Several technology players have been attempting to establish and scale a dry electrode manufacturing process that overcomes the high energy demand, low reliability, low flexibility, high carbon footprint and use of toxic materials of today’s wet coating processes. The biggest advances though, are only possible by combining material preprocessing and new high speed additive manufacturing. Dry electrode printing reduces energy consumption and carbon footprint, eliminates all use of toxins and forever chemicals while delivering full scalability and high volume cost efficiencies. Dry printing of electrodes is the first step to printing complete batteries, in arbitrary shape and form, including SSB materials, eliminating metal foils and integrate inherent safety features – all at competitive high volume efficiency.
Some Takeaways from This Presentation:
Scalable Manufacturing of Dry Materials: Maintaining electrochemical performance through dry-printed anodes and dry-printed solid cathodes.
Process Comparison: The complexity of wet electrode manufacturing vs. the simplicity of dry electrode printing.
Kavian Platform: A detailed comparison of dry process efficiency and advantages.
Fraunhofer IFAM | Printing technology as green alternative for thick layer Li Ion Battery electrode production
Mario Kohl & Daniela Fenske
The need for more ecological and sustainable production technologies is a general demand for competitive battery manufacturing factories in the future. The energy consumption and carbon dioxide emissions are cost-driving factors and at the same time have high increasing social impacts. Solutions for making electrode production greener can be realized by avoiding or replacing toxic and harmful materials, e.g. by aqueous processing. Also less solvent requiring processes may lead to less extensive drying efforts. Screen-printing technology for electrode manufacturing combines both environmental benefits and enables for thick film electrode production with high areal capacities especially for high energy cells (up to 5…8 mAh/cm 2 ). In this work it will be shown that the solvent amount can be decreased by about 20% by processing of highly filled pastes. In addition, it is possible to enable a multilayer printing and therefore sequential and fast drying as well as near-net-shape printing leading to less waste upon production. The thickness and high areal capacity of the printed coatings lead to new design aspects of the electrode structure affecting full cell performance. Some insights will be given with regard to current-rate capability, useable capacity, porosity and efficiency of ion- exchange pathways. The screen-printing process is a scalable and established series production technology. The high accuracy, energy efficiency and low emissions are strongly in line with the goals of green production.
Key Insights from the Presentation:
Sustainable production strategies – reducing harmful materials and improving efficiency.
Printed thick-film electrodes – advantages in performance, porosity, and capacity.
Fraunhofer IFAM’s electrode production process – includes mixing, coating, drying, and calendering.
Coating structure and performance of LFP cathodes – microscopic analysis and insights.
Advancements in all-solid-state batteries – key challenges and new production technologies.
Fully printed battery approach – highlights from the BMBF Project "3DPrintBatt".
Sandia National Laboratories | Multi-Scale Safety Evaluation of Commercial Sodium-ion Cells and Materials
Alex Bates
Key Takeaways:
Materials R&D – Assessing thermal stability and the impact of aging on battery components.
Cell and Module Testing – High-precision cell cycling and degradation analysis.
Simulations & Modeling – Fire dynamics simulations to predict the size, scope, and consequences of battery fires.
System-Level Design & Analysis – Enabling predictive maintenance for improved reliability.
Outreach, Codes & Standards – Aligning with industry best practices, including EPRI energy storage data submission guidelines.
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P3 automotive GmbH | Next-gen battery strategies 2027+ | Potentials and challenges for future battery designs and diversification in product portfolios to serve a large bandwidth of market applications
Behnoosh Bornamehr
Revolutionizing Automotive Energy Storage: Investigating the integration of Cell-to-Pack (CTP) and Cell-to-Chassis (CTC) concepts for heightened energy densities and cost efficiency, coupled with a heightened emphasis on mixed cell chemistry concepts both on pack and cell level. Next-gen technology development: Navigating fluctuating raw material prices with Sodium-Ion Batteries (SIB) and Embracing Innovations in Anode Engineering and (Semi-)Solid-State technology for diverse applications including EV business and beyond. Diversification of cell manufacturer’s product portfolio: Increasing significance of market segmentation addressing the variety of needs for applications such as Bus, Truck, Off-Highway and ESS, and the standard EV business.
Key insights from this presentation
Battery demand is projected to exceed 9 TWh by 2035, with the automotive sector leading the way. ESS and commercial vehicle applications are also expected to gain momentum.
Energy density has nearly doubled in the last decade, with new technologies poised to increase it by another 50%–100%.
Vertical integration strategies vary: some OEMs focus on system integration while relying on external suppliers, while others opt for greater in-house production control.
Orion Carbons | Engineered Carbon Blacks for Energy Storage Applications
Dietmar Jansen
Carbon Black is a critical component in lithium batteries, regardless of the specific technology employed, including Li-ion, solid-state, and post-Li. Despite the low ratio at which carbon black (CB) is added, it plays an indispensable role in the battery. To date, CB has not been a primary focus of LIB research. This perspective has shifted in light of the advancements in engineering that have reached a point where even inactive materials must be optimized to enhance key parameters in battery technology. This presentation will provide an overview of the underestimated, wide-ranging applications of CB, the crucial key attributes of CB for batteries, and their impact on the application field. This will also illustrate how the properties can be tailored to fulfill the different requirements of battery manufacturing steps. Examples of several CBs will be presented to demonstrate the possibilities of a customized production process.
Key takeaways from this session:
Unique properties of carbon black & its role in energy storage
Advanced conductive carbon black technologies
How CB enhances lithium-ion battery performance
A differentiated LIB portfolio
Analytical insights into CB manufacturing
The Future of Electronics RESHAPED USA. Mark your calendars for June 11-12, 2025, and join us at UMass Boston to explore the forefront of emerging technologies. Full event details are available on our website [here].
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