Module II: Upscaling solid-state batteries via new production technologies
Solid-state batteries are considered one of the most promising technologies for future energy storage systems. Compared with conventional lithium-ion batteries, they offer the potential for higher energy density, improved safety, and longer service life. Despite significant progress in recent years, one major challenge remains the transition from laboratory-scale cells to industrial manufacturing.
The Christian Doppler Laboratory for Solid-State Batteries investigates the scientific and technological challenges associated with the development of practical solid-state batteries. In its first research phases, the laboratory focused on understanding interfaces within solid-state batteries and developing manufacturing routes for multilayer pouch cells. Particular emphasis was placed on the relationship between materials, processing conditions, and electrochemical performance.
A key processing step during cell manufacturing is the densification and lamination of the solid electrolyte and electrode layers. Dense and mechanically stable layers are essential for achieving good ionic contact, low internal resistance, and reliable battery performance. While laboratory-scale densification methods such as warm isostatic pressing have proven highly effective for research, their suitability for large-scale industrial production is limited.
The new research module at the AIT Austrian Institute of Technology therefore focuses on the development of alternative manufacturing technologies that are compatible with continuous industrial production. The research investigates the use of double belt press technology as a continuous lamination process for solid-state battery components. In contrast to batch-based pressing techniques, continuous belt pressing offers the possibility of processing large-area battery layers under well-controlled pressure and temperature conditions while being compatible with high-throughput manufacturing.
The research aims to understand how processing parameters such as pressure, temperature, dwell time, belt speed, and drying conditions influence the densification of solid electrolytes and composite electrodes, the quality of the interfaces between battery layers, and ultimately the electrochemical performance of the assembled cells. By establishing these process–structure–property relationships, the project will provide the scientific basis for future industrial production of solid-state batteries.
The work is carried out in close collaboration with Berndorf Band GmbH, an international manufacturer of continuous double belt press systems. Combining Berndorf's expertise in industrial processing technology with AIT's battery manufacturing infrastructure and the scientific expertise of the Christian Doppler Laboratory creates a unique environment for developing manufacturing concepts for next-generation solid-state batteries.
Together, the activities at NTNU and AIT cover the entire pathway from the fundamental understanding of materials and interfaces to the development of scalable manufacturing technologies. The research will contribute to overcoming one of the major challenges in solid-state battery technology and support the transition towards industrial production.
