Although the global number of EVs has been increasing since 2010, EVs still have only 1.4% of global vehicle market share. This is mostly due to the fact that the development in the battery industry has been rather incremental, without revolutionary breakthrough since 1991’s launch of the first commercial Lithium-Ion batteries (LIB) by Sony. The advancement and maturity of the battery directly influence the industrialization of EVs. Thus, the biggest challenge the EV market is facing today is related to the limitations of batteries. These are mainly related to insufficient performance, in terms of size, energy density and safety (EV batteries are very flammable), and to expensive battery production, as available deposition methods generally fail to meet the requirements necessary to scale up and automate the production and require fixed casting on each battery specification type. Pulsedeon developed Coldab, a film coating process leveraging Ultra-Short Pulsed Laser Deposition (USPLD), that can optimize the production of LIB components on a large scale. Coldab’s unique PLD coating process allows cost-effective manufacturing of a new class of safer, smart tailored, high-performance EV batteries. Pulsedeon favors the competitiveness of European battery producers by offering a cutting-edge manufacturing process, and promotes a ‘clean environment’. In order to increase the EV’s affordability and improve their performance, Coldab brings EV’s battery manufacturing to a new level of scalability guaranteeing cost-effectiveness, at the same time preserving excellent performance by increasing the battery’s energy capacity and safety. During the phase 1 feasibility study, Pulsedeon will establish a sound go-to-market strategy and supply chain, and will draft further development plans. During the innovation project, Pulsedeon will optimize process automation, set up an industrial manufacturing line, and carry out in-vehicle testing with prospect customers.

Despite being an ideal solution to the global challenge of tackling the effects of transport emissions, Electric Vehicles (EVs) have not yet achieved significant mass market penetration. This is mostly due to the fact that the development in the EV battery industry has been rather incremental, without revolutionary breakthrough since 1991. LiBs represent the gold standard in the industry; however, they suffer from many issues which are detrimental to the widespread adoption of EVs. These are mainly related to insufficient performance, in terms of size, energy density and safety, expensive and rigid production while existing deposition methods has low production rate thus affecting the overall supply of EVs in comparison to high-growth demand (CAGR of 20%). Pulsedeon developed Coldab, a coating technology leveraging Ultra-Short Pulsed Laser Deposition (USPLD), that can optimize production of LiB & its components on a large scale. Coldab’s unique USPLD process allows cost-effective manufacturing of a new class of safer, smart tailored, high-performance EV batteries. Pulsedeon favours the competitiveness of European battery manufacturers by offering a cutting-edge manufacturing process and promotes a clean environment. To increase the EV’s affordability & improve their performance, Coldab brings battery manufacturing to a new level of scalability, at the same time preserving performance by increasing the battery’s energy density and safety. Overall objective of Pulsedeon is to introduce a paradigm shifting within EV battery manufacturing process to facilitate the widespread adoption of EVs. During the innovation project, Pulsedeon intends to upgrade & validate Coldab system to automate the production of LiBs & its components, conduct extensive validation tests of the system and produced LiBs, setup a scalable supply chain & finally conduct pilot tests with 8 battery OEMs confirming technology’s performance and advantages in a commercial environment.

Our intention is design and build pilot scale production line for next Gen 4a, 4b and 4c solid state batteries and battery components. Pilot plant is engineered based on already existing processing and equipments technology developed internally, in bilateral projects with customer and in EU funded collaborative projects. Pilot plan shall demonstrate full scale manufacturing technology for all-solid state, hybrid solid state and semisolid state as well as anodeless cell components for e-mobility and other feasible applications. Pilot plant is based on roll-to-roll and sheet-to-sheet capabilities utilizing novel processing technology for metallic Li and Li-alloys anodes (thermal evaporation and pulsed laer deposition), inorganic solid electrolytes (pulsed laser depositions), barrier layers (pulsed laser deposition and atomic layer deposition) and lithiophilic layers (pulsed laser deposition and thermal evaporation). Furthermore, novel postprocessing technologies including thermal, mechanical and thermomechanical tehcnologies are utilized for optimizing performance of cell materials & components. Process environment is controlled in order to allow reliable and safe handling of air and moistire sensitive cell material like sulphitic solid electrolytes and lithium metal and its alloys. Process environment is controlled at pilot plat level (dryrooms), locally at the cell material deposition chamber (vacuum or controlled gas atmosphere) and cell materials and assembly chambers. Customers are integrated into pilot plant product validation phase for all major battery concepts. Battery level testing and validation is extended to 100 Ah cells including energy and power density, cycle life and safety.

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 HyLiST project aims at developing Generation 4b all-solid-state lithium-ion batteries (SSBs) for road and aeronautic applications. These will be based on a high voltage (HV) spinel structured LNMO cathode, and hybrid single-ion polymer electrolyte (HSICP) and laser pulse deposited lithium foil on current collector as anode. Overall, processing is aimed at being scalable and easy to transfer to currently available manufacturing infrastructure in Europe. Wet coating for composite cathode preparation and dry processing for the hybrid solid electrolyte increase production efficiency and shorten developing periods. Solvents’ environmental impact is minimized, e.g. by elimination of fluorinated binders. A cobalt-free, high voltage (ca. 4.7V) LNMO cathode de-risks on the dependence of cobalt, and a single-ion polymer electrolyte helps to develop high Li ionic conductivity (≥0.5 mS/cm at room temperature) with a high transfer number (~1.0). Roll-to-roll PLD manufacture of thin and ultra-thin Li anodes will strengthen the European supply chain for semi-finished anode components. A granulation process prepares uniform hybrid solid electrolyte feedstocks to guarantee microscopic uniformity and thereby the resulting electrochemical performance. Environmental impact will be monitored and materials and processes multicriteria optimization performed. Digital twinning is built simultaneously for the simulation of cell production, with further iteration aiming at improved energy density and reduced cost. HyList identifies the essential steps for making all-solid-state batteries at a large scale. It provides valuable insights into efficient manufacturing methods and helps various industry players, like machine engineers, cell producers, and equipment manufacturers, to move toward safer batteries with enhanced storage capacities and high energy densities of 450 Wh/kg, suitable for both electric vehicles and aviation applications.