Fraunhofer Competence Center Battery Cell Production

The North American battery cell market is experiencing rapid and dynamic evolution: As of March 2023, industrial production capacities of lithiumion batteries with a cumulative capacity of approximately 1,700 GWh are either planned or already in operation. The surge in production capacities of battery cells is accompanied by a strong demand for pioneering advancements in both product and production technologies. New cell generations such as solid-state and sodiumion batteries are facing increasing attention by cell manufacturers, while in production there is at the same time an enormous demand for optimized manufacturing processes such as dry coating. In this fiercely competitive environment, innovation is the key to not only surviving but thriving.

Joining forces in the Fraunhofer Competence Center Battery Cell Production

The Fraunhofer Competence Center Battery Cell Production is a joint initiative of research facilities within the Fraunhofer-Gesellschaft for the further development of battery production in an international environment. The goal of the Fraunhofer Competence Center for Battery Cell Production is to become a central hub for cutting-edge research and innovation in North American battery cell manufacturing.

The Fraunhofer-Gesellschaft, based in Germany, is the world’s leading organization for applied research and development. With a total workforce of more than 30,000 employees, Fraunhofer develops key technologies across many industries, and then works directly with companies to commercialize world changing innovations.

The center of activities is the Fraunhofer Research Institution for Battery Cell Production FFB in Münster, Germany. The Fraunhofer FFB operates as an open battery factory for research and development purposes. Here, a team of 170 experts works on a wide range of battery research topics. The research facilities are currently being expanded to achieve production capacities of up to 7 GWh per year. As a second partner, the Fraunhofer Institute for Production Technology IPT, based in Aachen, contributes its many years of experience in pilot line equipment: For example, the Fraunhofer IPT has recently developed a system for the pilot-scale production of solid-state batteries.

The Fraunhofer Competence Center for Battery Cell Production is dedicated to supporting companies navigate the complex landscape of battery production, by focusing on three key challenges: orientation, industrialization, and operations.

Orientation: In an industry characterized by rapid change and uncertainty, companies often struggle with strategic decision-making due to volatile market conditions. We provide expert guidance to help businesses develop robust strategies, plan for sustainability, and navigate market entry, ensuring they are well-positioned to adapt and thrive in a dynamic environment.

Industrialization: The transition from research and development to largescale production presents significant challenges, particularly when scaling up next-generation battery cell technologies. These advancements often require entirely new manufacturing processes. At Fraunhofer, we assist companies in setting up state-of-the-art production equipment and refining their manufacturing processes, ensuring a smooth and efficient transition to mass production.

Operations: Once in operation, companies face the challenge of optimizing production while managing costs and reducing waste. Scaling processes are often cost-intensive, and high scrap rates can be a persistent issue across all Technology Readiness Levels (TRLs). We work with businesses to achieve operational excellence, focusing on process optimization and digitalization initiatives to minimize waste, lower costs, and improve overall efficiency.

Developing go-to-market strategies

We help companies identify opportunities in the battery market and formulate effective strategies for successful market entry. This includes conducting competitive analysis to understand the market landscape, identifying target markets to focus efforts where they will be most effective, and developing customized business models that align with company strengths and market needs.

Foresight and Assessment of Emerging Technologies

Our experts conduct in-depth analysis of emerging technologies, to help organizations stay ahead of technological advances and integrate cutting-edge solutions. This proactive approach ensures that companies leverage new technologies to increase their competitive advantage.

Technology Strategy Development

We work with companies to develop robust technology strategies that align with their long-term business goals, ensuring sustainable growth and innovation. Our strategic planning includes assessing current technology capabilities and identifying future needs to support ongoing development.

Sustainability Management

We guide our clients in their sustainability efforts, developing recycling and reuse strategies (Re-X), and ensuring compliance with regulatory requirements. Our support helps companies promote environmental responsibility, enhance efficiency, and meet regulatory standards, ultimately contributing to long-term sustainability.

We specialize in the design and implementation of customized equipment to scale up new battery concepts and process innovations. Our focus is on equipment capable of producing larger cell formats, from 5Ah up to larger than 50Ah, at a mid-volume production scale. This ensures that the production equipment meets the highest standards of efficiency, reliability, and performance, enabling companies to smoothly transition from prototype to mass production.