In order to boost the transition to a climate neutral transport sector, VERSAPRINT will bring innovations to the battery system to tackle safety issues, enhance performances as well as decrease cost and environmental impact. The VERSAPRINT technical solutions will be achieved mainly by 2D/3D printing directly on battery components and will operate from the heart of the battery system (i) providing an efficient cell thermal regulation in order to reduce risk of Thermal Runaway (TR) and increase density and lifetime; (ii) significantly improving the system thermal and safety management thanks to in operando sensoring; (iii) adding thermal and safety-oriented functionalities on busbars; (iv) allowing easy and safe dismantling and re-manufacturing; (v) lowering the casing’s weight, without losing its capability to contain TR and while ensuring good recycling rate; (vi) providing an advanced thermal/fire response; and (vii) controlling the exhaust gases released during a TR by cooling and evacuating them safely. VERSAPRINT will also implement a Decision Tool in order to choose the most optimised configuration for a given end application and will provide a validation at TRL5 (i) at module level with two module prototypes (for automotive and aeronautics) as well as one virtual module prototype (for waterway transport); (ii) at system level through simulation for all these applications. Other applications such as bus, non-road mobile machinery and stationary storage will be explored as well, through simulation. VERSAPRINT aims to reach the cost and performances targeted in Batteries Europe 2030 KPIs, while increasing module density by 5% and significantly improving the battery system fire resistance and safety (no fire outside module during TR). Sustainability will be assessed at all development stages. The multi-disciplinary consortium gathers 3 RTO/academic partners and 7 industrial partners (4 IND and 3 SMEs), and is completed by 12 industrial Advisory Board members.

The project main goal is to develop new generation batteries for battery storage with a modular technology, suitable for different applications and fulfilling the increasing need of decentralised energy production and supply for private households and industrial robotised devices.. New materials and components will be developed and optimised to achieve longer lifetime (up to 10,000 cycles depending on the material selected), lower costs (down to 0.03 €/kWh/cycle), improved safety and more efficient recycling (>50%). The expected results will strengthen EU competitiveness in advanced materials and nanotechnologies and the related battery storage value chain, preparing European industry to be competitive in these new markets. This will be achieved by using high capacity anodes coupled with cobalt free cathode and with a very safe gel polymer electrolyte separator, leveraging partners’ knowledge in advanced materials. This new technology will be developed up to a TRL 6 (large prismatic cell ESP-Cell 30Ah) at the end of the project, producing these novel high voltage high capacity batteries close to practical applications. Further, the proposed solution will allow Europe to become more independent from raw material and the feasibility of a metal recovery process will be deeply investigated and recommendations for future application will be made. To achieve the ambitious targets, the CoFBAT project covers the entire value chain, bringing together industrial experts in material development and battery science together with engineering companies and institutes and battery producers and integrators.

To date, the battery market is dominated by lithium-ion (Li-ion) chemistries, as the energy density has more than doubled and their costs have dropped by a factor of at least 10. However, conventional Li-ion batteries (LIB) are reaching their performance limits in terms of energy density and facing safety issues, is required the development and production of new battery generations, such as Solid-State Batteries (SSBs), to create a new industry value chain in Europe towards their commercialization. Consequently, high-energy-density EU-made SSBs will ensure the supply of, among others, the automotive sector. To do so, the development and deployment of new manufacturing technologies, enabling the large-scale production of SSBs, is crucial. Indeed, among the overarching themes to develop and produce sustainable batteries in the future, the BATTERY 2030+ roadmap4 considers manufacturability as a cross-cutting key area. Innovative and scalable manufacturing techniques to produce SSBs will accelerate cost reduction, energy savings, and enhanced safety. ADVAGEN will develop a new lithium metal (LiM) battery cell technology based on a safe, reliable, and high performing hybrid solid-state electrolyte (LLZO-LPS based), gaining a competitive advantage over the worldwide (mainly Asian) competition. This will sustainably strengthen the EU as a technological and manufacturing leader in batteries as specified in the ERTRAC electrification roadmap and SET-Plan Action Point-7. ADVAGEN consortium contains key EU actors in the battery sector, from industrial materials producers (SCHT, CPT, ABEE), battery manufacturer (ABEE) to R&D centers (IKE, CEA, IREC, TUB, CICe, POLITO, INEGI, UL, FEV) and the automotive industry (TME), covering the complete knowledge and value chain. By developing high-performance, affordable and safe batteries, ADVAGEN aims to re-establish European competitiveness in battery cell production.

One of the main challenges of EU battery sector to achieve the net-zero emissions objectives for 2050 consists of keeping the added value of EoL batteries, enabling their 2nd life, and improving recycling and recovery of critical materials. REINFORCE aims at designing, developing and deploying a novel sustainable, and highly efficient circular value chain serving as a reference for automated, safe and cost-efficient logistics and processing of EoL batteries from EV and stationary applications for repurposing and recycling. REINFORCE will demonstrate all technological solutions and processes in a real environment at TRL6, and the viability of the new circular value chain and business model innovations for EoL battery repurposing. This will be achieved by: (i) an optimisation of collection and reversed logistics focussed on efficient diagnostics for early battery status cut-off decision-making and safe and smart transportation solutions; (ii) safe and improved battery diagnostics and speed-up discharge and energy recovery systems adapted to the current batteries stream; (iii) adaptable and safe dismantling and sorting of EoL batteries and components based on robotics, Machine Learning and Industry 4.0, including fully automated pack-to-module disassembly and advanced module-to-cell-to-electrode disassembly; (iv) an innovative traceability system along the battery value chain based on a battery passport for the 2nd and 3rd life battery user; (v) the definition of standardisation guidelines in line with current and upcoming regulations; all revolving around (vi) robust sustainable circular business models demonstrating the application of REINFORCE proposition in a circular economy strategy and implement actions towards full market maturity. For this, REINFORCE is bringing together a wide experienced consortium led by INE, involving a team of leading industrial technology developers and providers, R&D centres and academic institutions, and end-users, at European level.

SPINMATE aims to demonstrate a scalable, sustainable, safe and cost-effective digital-driven proof-of-concept pilot line, at a TRL6 level, as a first step towards the large-scale manufacturing of generation 4b (Gen 4b) SSB cells and module, in order to support the electrification of the automotive sector. To do so, SPINMATE proposes the development and implementation of innovative and scalable manufacturing and processing solutions (notching/cutting, stacking and sealing/packaging steps, among others). Furthermore, new industry 4.0 and 5.0 concepts (Industrial Internet of Things – IIoT and Machine Learning – ML algorithms, Digital Twins, giga-factory line simulation,…) are proposed to be applied for the digitalisation of the proof-of-concept pilot line, as well as the assembly and manufacturing processes. Thus, SPINMATE will manufacture small 1 Ah and large 10 Ah SSB cells, after the development and optimisation of (i) advanced solid polymer electrolyte with high ionic conductivity and wide electrochemical stability, (ii) Li metal foil with surface treatment enabling a more stable interface as anode and (iii) Ni-rich layered oxide cathode with improved cycling stability. Regarding electrodes (i.e. anode and cathode) and electrolyte processing, innovative solvent-free extrusion routes, roll-to-roll approach and optimised solvent casting methods are suggested. SPINMATE’s Gen 4b SSB cells will create a new industry value chain in Europe towards their commercialisation. This new generation technology will ensure (i) enhanced energy densities, overcoming current LIB limitations, (ii) improved safety in both solutions and workers; (iii) increased sustainable mass production; and (iv) decreased carbon footprint and cost.