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Study on Solid-State Batteries: Producers Must Become Innovative

Study on Solid-State Batteries: Producers Must Become Innovative

The Chair of Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University has successfully completed a consortium study on the future production of novel solid-state batteries (SSB) in Europe. Together with numerous industrial partners, the research team examined crucial challenges and developed unique selling points for domestic manufacture as well as a European alternative to the recently announced “China All-Solid-State Battery Collaborative Innovation Platform” (CASIP).

The focus is now on the need for innovative manufacturing processes and their scalability, because up to 60 percent of the current production layout for lithium-ion batteries may have to be significantly changed.

PEM Director Professor Achim Kampker, says:

After years of basic research on the most powerful solid-state electrolytes, the most important material questions have been largely clarified,

”The focus is now on the need for innovative manufacturing processes and their scalability, because up to 60 percent of the current production layout for lithium-ion batteries may have to be significantly changed.”

The development of solid-state batteries based on lithium-ion technology is also considered an important factor for future electric mobility, as the batteries are said to be safer and theoretically enable longer ranges as well as shorter charging times.

Sales potential of 550 billion euros in 2035

According to the consortium study, partnerships for the commercialization of solid-state batteries are currently emerging worldwide, each pursuing their own approaches. While the focus in Europe and the United States is mainly on polymer and hybrid electrolyte systems, in Asia – especially in China – sulfide-based systems are increasingly being researched. By 2035, solid-state batteries could already account for a significant share of the global battery market, with a potential total output of up to 1,200 gigawatt-hours, says Kampker,

The sales potential is then expected to be around 550 billion euros, so even a small share of that is very attractive.

However, manufacturers will need innovative and scalable plant technology to achieve this, the study claims.

Current challenges in the production chain

The study also reveals numerous challenges in the production chain. For example, new processing methods are needed to produce thin and dense layers for solid-state electrolytes and lithium metal, and it is necessary to examine the extent to which dry coating approaches from the current production of lithium-ion batteries can also be transferred to the production of solid-state electrolytes. Heat treatment steps also need to be optimized, especially for ceramic-based solid-state electrolytes, and for electrode stacks, interfaces with low resistance must be ensured for optimal ion conduction of the solids. In addition, customized production processes are needed for new hybrid cell formats that combine pouch and prismatic designs, and bipolar cell stacks will influence cell assembly as well as formation processes in the future.

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