Cell Concepts and Prototypes

The working group focuses on the design, prototyping, and testing of new battery cell concepts and their small-batch production. A special feature here is that the entire manufacturing process – from ceramic raw materials to component construction and final assembly to the initialization and testing of the finished cells – takes place in-house from a single source on a pilot plant scale. Solid electrolytes made of Na-ß-aluminate form the core of our cell technology. These are manufactured at Fraunhofer IKTS in a wide variety of geometries (mainly tubular and planar) and in medium to small quantities by isostatic pressing and extrusion.

Other research priorities of the group in the battery context include, for example, the aqueous, tube-slit extrusion-based production of battery electrode foils from the cathode active materials LFP (lithium iron phosphate) and NMO (sodium manganese oxide). The latter is of particular interest to us and is being researched in our laboratories and produced in small quantities. The aim is to establish sustainable processes and gradually reduce critical raw materials through targeted doping with alternative metals.

The “Cell Concepts and Prototypes” group has decades of experience in the shaping of ceramic components. This focus includes both research projects and direct industrial contracts. The entire shaping process is available: from initial planning and raw material qualification and modification (Al₂O₃, BSCF, MgO, CSFM, NMO, LFP, etc.) to the actual, highly flexible shaping (honeycomb structures, tubes with or without end caps, rods, rings, sleeves, etc.) using cold plastic extrusion, casting, and isostatic or uniaxial pressing (hot (vacuum) or cold), as well as quality control.

In addition to the pilot plant for powder synthesis and extrusion, the group also operates a comprehensively equipped workshop for processing ceramics and metal. The workshop has pilot-scale machines for cutting (conventional and plasma), milling, turning, drilling, bending, welding, and joining ceramic and metal materials. The creation of construction drawings, the design and construction of components, reactors, systems, and tools are also carried out here.

• Design, development, prototyping, and testing of sodium-based battery cells and ceramic molded parts for research projects and industrial orders
• Small-batch production of battery cells
• Development and production of active materials for sodium-based battery cell systems (e.g., NMO)
• Development and production of battery electrode foils made of NMO, LFP, etc.
• Material analysis, mechanical and electrochemical characterization of battery cell components/systems, cathode active materials, and ceramic molded parts
• Market analyses, feasibility studies, and consulting on issues related to battery storage and ceramic molded parts
• Creation of construction drawings as well as design and construction of components, reactors, systems, and tools made of both metal and ceramics
• Material qualification 

Extrusion of Aqueous-Plasticized LiFePO₄ Foils as an Environment-Friendlier Alternative to Casting for the Industrial Production of Li-Ion Battery Electrodes. Part 1: Material Qualification and Foil Extrusion

cfi/BER. DKG 102 (2025) No. 2