The SOLiD project will create a sustainable and cost-efficient pilot scale manufacturing process for a high energy density, safe and easily recyclable solid-state Li-metal battery. We will use roll-to-roll (R2R) dry extrusion coating for the blend of cathode active material, solid polymer electrolyte, and conducting additives. R2R slot die coated primers on the cathode current collector will enhance adhesion, performance and corrosion resistance of the cell. The polymer electrolyte layer will be R2R coated, using an optimal design for the slot die head. For the Li metal anode, we will utilize cost-efficient R2R pulsed laser deposition, which enables minimizing the Li thickness down to 5 µm. The Li metal production will be combined with an inline process for interfacial engineering to ensure compatibility with the other layers and stability. The process development will be supported by digitalization methods to go towards zero-defect and cost-efficient manufacturing. The proposed methods enable sustainable manufacturing of Gen. 4b solid state batteries with minimised amount of critical raw materials (Co and Li), and with superior performance and safety: The protective layers enable the use of NMC811, which reduces the amount of Co into minimum without compromising the lifetime, and PLD process helps to minimize the Li thickness. Dry coating eliminates the use of toxic solvents and energy-consuming drying steps, and the digital quality control will reduce the amount of waste. The thickness of each layer will be minimized to reach energy density above 900 Wh/l. Cost will be reduced by cost-effective production methods and by maximizing the yield. Safety and long cycle life are guaranteed by the solid electrolyte and the protective interlayers. Supported by the life-cycle thinking and stakeholder engagement, the SOLiD project will enable the design for a sustainable solid state battery factory of the future.

The greatest challenges towards the worldwide success of battery-powered electric vehicles revolve around the safety, energy density, and cost of the battery technologies. Solid-state polymer electrolytes and lithium metal anode address these challenges by replacing the flammable and unstable liquid electrolytes and enabling dendrite-free cycling of high-energy lithium metal cells manufactured by sustainable and cost-effective processing. The PSIONIC project advances the development of all-solid-state battery technology by employing amorphous cross-linked Polyethylene oxide (PEO) laminated on the thin lithium foil at the anode and high voltage cathode coated with a single-ion conductive polymer. This will allow to replace the flammable and unstable liquid electrolytes and enabling dendrite-free cycling of high-energy lithium metal cells manufactured by sustainable processing. Special attention will be devoted to the optimization of interfaces between the active material and polymer electrolyte. Materials selection will enable the use of the manufacturing technology available at BlueSolutions, which is readily scalable, based on sustainable processing using solvent-free extrusion. PSIONIC is aiming to develop cells with a safety hazard level 2, since no liquid component will be in the cell at the end of the project. The research and innovation actions carried under the PSIONIC project will not only just contribute to the technological advancements of all-solid-state Li-ion batteries in terms of safety, reliability, performance, cost, and sustainability, but will also enable higher uptake by the electromobility sector and end consumers, paving a pathway towards climate neutrality, and green energy transition.