A limiting factor in the manufacture of high-capacity cells in pouch format is the internal contacting of the current collectors with the arrester tab. Ultrasonic welding has proven to be a robust and quality-assured process there. At the same time, the number of weldable foils is limited, especially on the anode side. However, laser structuring of the copper foils in the area of contacting can roughen the surface and produce a better contacting quality. This effect is reflected in increased mechanical strength and reduced electrical resistance.

3D architectures in high-mass-loaded electrodes have significant impact for electrochemical performance of lithium-ion batteries, such as cycle lifetime, lithium-plating, cell degradation, and high-rate capability. Fast charging and high power operation for high energy batteries with thick-film electrodes becomes possible. Ultrafast laser structuring of cathodes and anodes in roll-to-roll processes is currently being upscaled to push this technology towards TRL6 and beyond.

In this talk, Alkegen will report on two things: 1) the rapid progression in material scaling and US-based manufacturing of SiFAB silicon anode materials in New Carlisle, IN, and 2) cell performance of the manufactured SiFAB silicon anode material with respect to rate capability, fast charge, swelling, and cycle life.

Giga factories require highly effective leak tests for cell packs and trays to catch up with China. This presentation shows solutions to advance the throughput of modern factories and fundamental principles of testing. Newest principles accelerate the high volume production and ensure batteries are safe and leak-proof. This presentation illustrates the physical principles and their practical application in machinery to build modern Li-ion batteries.

Along with the increasing demand, announcements of the global battery supply outline lithium-ion battery production capacities of over 6 TWh in 2030. Many cell manufacturers struggle with major obstacles while striving to achieve their announced production capacities. Especially quality losses during the initial years of operations significantly impact the business plan. The major challenge for the cell manufacturers and equipment suppliers is to identify these potential quality threats and mitigate the risks. An integrated quality and traceability system to measure quality KPI’s and consider them for product and production optimization is key to a successful production ramp-up.

This study focuses on the development and prototypical implementation of two new drying processes based on electromagnetic induction and conductive heating. Inductive and conductive drying experiments were carried out on lithium-ion battery electrodes, which were subsequently characterized regarding their mechanical and electrical properties. Based on the results, the transferability of the already known influence of the convective heating process on the properties of the electrodes to the inductive and conductive heating processes is evaluated.

Eddy current is shown to be a feasible non-destructive testing technique for automated quality control of cell foil tabs that have been ultrasonically welded. The technique identifies over-welding, under-welding, missing foils, and lack of fusion.

80% of the challenge in machine vision is lighting. A good lighting, when coupled with state-of-the-art AI software, solves visual inspection with low false acceptance and false rejection. This talk covers the advances in lighting and unique approaches to imaging.

The rapidly growing EV market has incited an equally accelerated need for the construction of battery gigafactories, which are critical components in closing the supply-demand gap for energy storage. Building these gigafactories demands careful planning, almost flawless execution, and a deep understanding of the construction landscape, material and equipment supply chains, and team culture.

A deeper dive from the state-level perspective of the new policies built to encourage industry growth as well as an introduction to the incentives and workforce training programs commonly used to attract and grow the battery industry.

The manufacturing process of lithium-ion batteries is a complex procedure that encompasses multiple steps and various parameters. It is crucial to develop tools that can facilitate the preparation of future gigafactory workers for this intricate task. In this presentation, I will introduce a series of innovative virtual reality digital twins that have been developed in my research group. These digital twins give the promise to revolutionize the effective teaching of battery concepts and the efficient training of battery scientists, engineers, and operators.