Battery Vault’s Post

🔋 New White Paper: Mastering the Ramp-Up of Battery Production I'm excited to share that our partners at Fraunhofer Research Institution for Battery Cell Production FFB and PEM RWTH Aachen University have published a must-read white paper on the critical topic of scaling up gigafactories for battery production. As global demand for batteries skyrockets, the successful ramp-up of battery production facilities is key to ensuring the competitiveness of the European electric mobility sector. This white paper dives into the challenges of high reject rates, the need for skilled labor, and the role digitalization plays in optimizing production. For the lazy ones - Some striking insights ;) - Scrap rates of 15-30% are common in the early ramp-up years, costing up to €900,000/day at full capacity. - Digital quality assurance and traceability are vital to reducing costs and improving efficiency. This publication, based on real-life case studies and best practices, provides a comprehensive roadmap for overcoming technical and operational hurdles. Read the full white paper here: https://lnkd.in/eB_Vjxg8 Let's discuss how these findings can help drive the future of battery production and ramp-up processes! Feel free to reach out if you'd like to connect. #BatteryProduction #Electromobility #Gigafactories #Digitalization #Innovation #Sustainability

"Setting aside the complexities of digital sovereignty and geopolitical considerations, a diverse, global EV ecosystem—where products are manufactured, utilized, and repurposed near the end user—benefits everyone." Rory Francis Comiskey MAY2024 #BatteryProduction #Innovation #Sustainability #Sustainability #DigitalTransformation #EVecosystem #EV #EVbattery #Battery

🔋 Future of Solid-State Battery Production in Europe: RWTH Aachen University Study The Department of E-Mobility Component Production Engineering at RWTH Aachen University, in collaboration with industry partners, has completed a study on the future of solid-state battery production in Europe.   📌 Key Findings from the Study 🔹 Innovation Focus Shift: After years of material research, particularly on solid-state electrolytes, fundamental scientific questions have been largely addressed. The focus is now on scaling up production processes to meet industrial demand. 🔹 Production Challenges & Modifications: Transitioning from lithium-ion to solid-state battery production requires modifying 60% of current production processes. Dry coating techniques, currently used for lithium-ion batteries, could be adapted for solid-state electrolytes. Optimization of heat treatment and electrode stack interfaces is critical to ensure low resistance and high ionic conductivity. 🔹 Global Market & Regional Approaches: The global solid-state battery market is projected to reach €550 billion by 2035, with a total power capacity of up to 1,200 GWh. Different regions are pursuing distinct technological paths: Europe & USA: Focus on polymeric and hybrid electrolytes. China & Asia: Advancing in sulfur-based battery systems. 🌍 Strategic Implications for Europe ✅ Autonomous Production: European manufacturers have an opportunity to establish an independent supply chain, reducing reliance on Asian imports. ✅ Competitive Edge in E-Mobility: Solid-state batteries offer higher safety, greater capacity, and faster charging, making them a key EV industry driver. ✅ Collaboration & Investment Needed: Further research & industrial partnerships are essential to accelerate large-scale manufacturing feasibility. As Europe moves towards next-generation battery production, strategic advancements in manufacturing techniques, material science, and supply chain independence will determine its global competitiveness in e-mobility and energy storage. #SolidStateBatteries #EUBatteryIndustry #E-Mobility #BatteryTech

Automotive technology is at an interesting crossroads, facing a clash between two technological philosophies. On one side is the nearly perfected combustion engine technology with limited room for further development, and on the other is the promising but still undercooked battery technology. Battery-powered cars face several issues:  👉 Range (battery capacity), 👉  Battery lifespan, 👉  Fire safety,  👉 Battery weight,  👉 Strain on the power grid,  👉 Use of rare earth metals. Currently – and we say it as automotive insiders – there are no plans to introduce a new battery type. Research and development are neither fast nor cheap, and technological revolutions take time. Scientists at the University of Hong Kong have developed a new generation of lithium-metal batteries that retain 99.8% efficiency after 450 charge-discharge cycles, even at 100°C. Key to this are crack-free polymer electrolytes, ensuring high electrochemical stability and safety. These batteries resist dendrite formation and are non-flammable, making them a potentially revolutionary solution. The process for creating crack-free polymer electrolytes is relatively simple and expected to be cost-optimized. Can we say this solves most problems? No. The point is to show that engineering doesn't sleep and breakthroughs come from braining 🧠🧱 so hard the technological ceiling begins to crack. New solutions require invention, long-term testing, and then implementation. The new generation of batteries won't appear tomorrow, but they will come! #automotive #news #electromobility #engineering #batteries

🚀 Recently, I had the opportunity to complete the "Battery Production" course, led by Heiner Heimes from RWTH Aachen University, in collaboration with Tecnológico de Monterrey. Throughout the course, I gained an in-depth understanding of the 🔋 lithium-ion battery manufacturing process for automotive applications. Over six modules, I acquired key knowledge on: ✅ Functionality of lithium-ion battery cells. ✅ Manufacturing processes: from electrode production and cell assembly to module and pack creation. ✅ Industry insights: an updated analysis of the 🌍 global battery market as of 2024. This learning experience not only allowed me to strengthen my theoretical knowledge but also to demonstrate it through practical activities and final evaluations. ⚡ I am excited to apply these insights to projects related to electric mobility and energy sustainability. #Innovation #ElectricMobility #Batteries #eMobility #BatteryProduction #Recycling ♻️ #BatteryRecycling

Fraunhofer-Institut für Produktionstechnologie IPT acts as a facilitator for battery cell production within the Fraunhofer battery cell ecosystem 🔋. Rather than manufacturing our own batteries or developing new cell materials, we enable companies to produce them by, for example, developing specialized machinery for new cell technologies or implementing digital solutions to improve production quality. 💡 Our projects in the field of mechanical and plant engineering are a perfect example for our role as an production enabler. We have many years of experience in the design and construction of new production equipment to scale up product and process innovations. Most recently, Fraunhofer IPT has developed a special machinery for the production of sulfidic solid-state batteries. Overall, our offer to industry can be segmented into three market phases: ◾️ Orientations (market entry strategies, technology strategies) ◾️ Industrialization (pilot lines, special-purpose machine construction, sample production) ◾️ Operations (digitization, measurement technology, operational excellence) 👉🏼 Discuss the challenges of production with our battery expert Frederik Bennemann. Feel free to contact him on LinkedIn! #Production #EnablingTechnologies #Pilotlines #FraunhoferBatteries 

Digital twins are making waves in battery manufacturing, cutting production costs by up to 80% and increasing development efficiency by 25%. The benefits are undeniable—see some key stats below.   You can read more about how digital twins are shaping the future of the battery industry in our latest article. (The link to the article is in the comments) #battery #energystorage #Innovation #Research #DigitalTwins #PreScouter

Battery 🔋 #manufacturing process chains and factories 🏭 will definitely have a different outlook in the near future. This is as a result of introducing new “production” technologies in the effort to reduce cost and environmental footprint of #batteries. Our paper presents a “#Model-based approach for technology assessment in battery manufacturing process chains and factories”, to aid decision makers in gaining valuable insights on the impact these technologies may bring in their factory. Furthermore, equipment manufacturers and researchers may also have several questions answered through this approach. The paper is accessible free, through the link below 👇🏾. https://lnkd.in/eYe-4nen Sebastian Thiede Yang Shun Factory2030 - NXTGEN Hightech University of Twente

𝗗𝗶𝗴𝗶𝘁𝗮𝗹𝗶𝘇𝗲𝗱, 𝗦𝘂𝘀𝘁𝗮𝗶𝗻𝗮𝗯𝗹𝗲 𝗕𝗮𝘁𝘁𝗲𝗿𝘆 𝗖𝗲𝗹𝗹 𝗣𝗿𝗼𝗱𝘂𝗰𝘁𝗶𝗼𝗻: The further development and evolution of existing storage systems is a key prerequisite for the energy transition. The Center for Digitalized Battery Cell Manufacturing (ZDB) at the Fraunhofer Institute for Manufacturing Engineering and Automation IPA and acp systems AG have joined forces to commission a winding system for cylindrical battery cells featuring flexible formats and design. It serves as an innovative research and production platform to test new cell formats and components along with tab designs and also enables development of large-format cells for future battery technologies. The winding system is the first of its kind in the world. It is embedded in an automated, digitalized battery cell production infrastructure. 𝗥𝗲𝗮𝗱 𝗺𝗼𝗿𝗲: https://lnkd.in/epk8ksvx Fraunhofer IPA, Julian Grimm

I am Martin Köhne, project leader in disruptive conductor materials for e-mobility at Bosch Research. My current research focuses on disruptive electrical conductor materials based on graphene or carbon nanotubes. Used in electric drive trains, they have the potential to reduce the conductor mass to a quarter of that of copper and significantly improve efficiency thanks to their higher electrical conductivity. In the medium term, these conductor materials will become part of electric powertrains. In the revolution of the e-mobility era, as a technology "Invented for life", they make an important contribution to protecting the environment and conserving natural resources. To learn more about me and my work, click here ➡️ https://lnkd.in/e8FkcFpr #Experts #BoschResearch