HoWaLIB – Upscaling of roll structuring in electrode production for lithium-ion batteries

In the HoWaLIB project, a concept for scaling up the roll structuring of electrodes in lithium-ion battery production to high-throughput operation is being developed. This aims to reduce production costs, save resources, and lower CO₂ emissions.

Driven by climate change, lithium-ion batteries are increasingly becoming a key technology for energy storage and energy provision. A major challenge lies in manufacturing lithium-ion batteries that combine high energy density with high power density. One promising approach to address this challenge is the targeted modification of electrodes by introducing defined microstructures, which can enhance electrochemical performance. This enables the realization of thicker electrode layers, thereby increasing energy density without adversely affecting power density.

Among the available structuring approaches, roll structuring is particularly promising, as defined microstructures are directly introduced into the electrodes during the calendering process. This eliminates the need for an additional processing step, avoids material removal and particle generation, and achieves electrode modifications comparable to other structuring methods that require a dedicated production step.

Initial proof-of-concept studies at laboratory scale were conducted within the research project ProfiStruk (funding code: 03XP0244A). These studies demonstrated that roll structuring effectively increases charge rate capability and extends battery lifetime. Building on these results, the HoWaLIB project (funding code: 03XP0638B) further advances roll structuring toward industrial application. The focus is placed on increasing process speed and developing a concept for high-throughput production. To this end, the degradation and contamination behavior of the embossing roller are systematically investigated, and suitable cleaning and maintenance strategies are developed.

In parallel, manufacturing expertise for suitable structuring rollers is being established to support the design of an industrial-scale structuring calender. The developed concepts are subsequently validated together with the Fraunhofer Research Institution for Battery Cell Production (FFB) in an industry-oriented environment.

The project is funded under the Clusters Go Industry funding scheme, which aims to transfer research results from national battery clusters into industrial applications in close cooperation with industry partners and to strengthen battery research in Germany. The HoWaLIB project makes a significant contribution to the technological sovereignty of the German plant engineering sector by developing an independent solution for battery cell production. This strengthens industrial competitiveness, reduces production costs, saves resources, and contributes to reducing CO₂ emissions.

 

Acknowledgments

The HoWaLIB project is funded within the umbrella concept of battery research under the framework program “Vom Material zur Innovation” by the German Federal Ministry for Research, Technology and Space (BMFTR). The funding scheme is coordinated by Clusters Go Industry and implemented by Project Management Jülich (PtJ). We thank the BMFTR, the NOW GmbH and PtJ for their support and the constructive and trusting collaboration. Furthermore, we would like to thank the project partners, Matthews International GmbH, the Fraunhofer Research Institution for Battery Cell Production (FFB), and MANUGY GmbH for the excellent cooperation within the project.

Project details

Duration	01.01.2025 – 31.12.2027
Project partners	Matthews International GmbH, MANUGY GmbH, Fraunhofer Research Institution for Battery Cell Production (FFB) and Technical University of Munich (Institute for Machine Tools and Industrial Management)
Funded by	German Federal Ministry for Research, Technology and Space (BMFTR) – Funding initiative "Clusters Go Industry"
Project management	Project Management Jülich (PtJ)