Innovation
through research
customcells® RESEARCH PROJECTS
The existing performance capacity of mobile end devices, drones, electric vehicles or within the framework of stationary storage of renewable energies would not exist today without correspondingly powerful lithium-ion batteries. The range of lithium-ion batteries is divided into different cell types depending on the application. Depending on the application area of the cell, various components and material combinations are used.
The numerous combination possibilities result in many possibilities for the optimization and adaptation of lithium-ion cells - also with regard to their specific application. The development of post-lithium systems also offers enormous optimization potential. The investigation of new bonding systems for electrode production, the generation of higher SI components of the anode to increase capacity or the investigation of magnesium-sulfur cell chemistry are just a few examples of the potential development opportunities in the lithium-ion battery segment.
In order to remain at the forefront of technological development, CUSTOMCELLS®, together with numerous interdisciplinary partners from research and industry, is continuously involved in public cooperation projects to research new materials and concepts and to develop new innovations for special applications.
ONGOING FUNDING / RESEARCH PROJECTS
In the context of technological development, CUSTOMCELLS® is involved in various funding and research projects. The following is an overview of the current projects.
GUTBatt
With participation in the GUTBatt project, CustomCells continues to aim for in-depth technical knowledge and further development of the dry coating process in-house. The project brings together all the necessary expertise from industry and science for the integral development of a dry coating process for electrodes for use in lithium-ion batteries (LiBs) and lithium-polymer solid electrolyte batteries (SSBs). The primary goal is to develop a scalable dry coating process for the production of battery electrodes using different innovative materials. The knowledge acquired from a similar project coordinated by CCI, ‘‘ProLit‘‘ will be used as a basis for targeted process optimization. The entire consortium will examine possible solvent-free process routes and safety concepts, and a dry coating process for LIB will be established on a laboratory scale. For this purpose, the active material (AM) graphite will be used on the anode side and higher nickel AM on the cathode side. Based thereon, the dry coating process will be scaled up on the mixing process side and the resulting powder mixtures processed on a pilot calendar using the dosing technology developed in the project. The established process route will also be tested for polymer SSBs. On the anode side, a novel silicon-containing anode AM will also be transferred to the process route. The purpose therein is a complete understanding of the material-structure and process-structure-property relationships. In addition to this, an integral analysis of the process chain will be carried out to determine the scalability and adaptability of the process. Finally, based on data obtained from the project, a cost/benefit evaluation of the dry electrode production and a comparison with the conventional liquid-based process route will be performed.
ProMoBatt
As part of the ProMoBatt project, the process step of cell stack formation will be systematically and sustainably optimized by developing performant process models. Customcells will deal with the optimization of the already existing Z-folder. By creating a digital twin as well as integrating new inline analytics, an increase in stack accuracy and speed as well as a reduction in production waste will be achieved. As a result, not only can cells be produced with higher quality and safety, but cell production can be made more sustainable at the same time.
TwinTRACE
The "TwinTRACE" joint project brings together industry and researchers to shape the factory of the future and sets itself the goal of developing a digitization technology with which the quality and traceability of a variant-rich battery cell production can be brought to a world-leading level. To this end, technical solutions are being developed and validated at the three innovation levels of transparency, networking, and autonomy. For the innovation level of transparency, the process and product data are to be fully recorded in forward production and the traceability of each material/product component is to be made possible. With the innovation level networking, the collected data is used to develop a virtual representation (digital twin) and consequently to map the system behavior, taking into account logical and physical processes. This virtual representation offers manufacturers the possibility of maintaining products and systems in advance, as well as determining production quality, machine availability, and the qualitative classification of the end product in advance. The last innovation level, autonomy, is intended to achieve a direct influence on the process and product quality by having autonomously acting solutions take over process control in real time based on data and bring about a significant increase in quality.
NEWBORN
In NEWBORN, CUSTOMCELLS® is developing a certifiable battery to support a fuel cell powered powertrain in the aviation sector. NEWBORN focuses on realistic and commercially viable project outcomes significantly exceeding the Call topic Expected Outcomes. This is the only path to bring a real impact, well beyond paperwork and test rigs. With this in mind, the project applies the steppingstone principle and intends to bring aviation graded fuel cells into the market as soon as safely possible. This will generate operational data to support certification on CS-25 aircraft. It will further provide vital acceptance gap mitigation in the conservative air transport environment. The 18 multi-disciplinary partners, including 3 non-traditional aerospace partners and 2 SMEs, will work on 28 key enabling technologies. They will be matured and optimized to support an EIS of CS-23 aircraft by 2030 and regional aircraft by 2035. The ambition of the project is to achieve an overall propulsion system efficiency of 50% by 2026, calculated as a ratio of energy on the propeller shaft to the hydrogen lower heating value. This ambition greatly surpasses the expected outcome of the HPA-02 Call. Similarly, by the end of 2025, the project will demonstrate widely scalable fuel cell power source technology with a power density of >1.2 kW/kg and stack power density of >5 kW/kg. Technologies will be adaptable to different maximum flight altitudes of ≤ FL250 and ≤FL450, and scalable down to ~250kW and reusable for secondary power in SMR flying altitudes by 2026. An innovative cryogenic tank concept will be integrated, demonstrating a gravimetric index of 35% for the CS-23 aircraft and scalable up to 50% for regional aircraft. The project will also address high power density high voltage energy conversion, propulsion systems, and the next generation microtube heat exchangers, along with an accurate digital twin of the overall system. Altogether, NEWBORN will develop a technology demonstrator prepared for flight demonstration in Clean Aviation Phase 2.
RevoLect
The aim of the revoLect research project is to create new types of electrodes with lightweight fabric-based current collectors for lithium-ion batteries (LIB) and to significantly increase the specific energy density. The work will be divided into corresponding subprojects of the individual partners. The aim in the subproject of the partner CUSTOMCELLS® Itzehoe GmbH is to carry out a coating of the novel substrate with an electrode paste under industrial conditions. In subsequent electrochemical measurements, the performance of battery cells with the ultralight fabric-based current collectors is to be investigated. This will not only demonstrate that the material can be processed as a substrate for lithium-ion batteries, but also that it is worthwhile.
NoVoc
NoVOC (Eliminating VOC from Battery manufacturing through dry or wet processing) - CUSTOMCELLS® further develops dry processing of electrodes with the aim of sustainable and solvent-free battery production. The project NoVOC addresses the Topic Environmentally sustainable processing techniques applied to large scale electrode and cell component manufacturing for Li ion batteries. The activities of NoVOC are tailored to the challenges addressed by the call topic: 1. Lower carbon footprint cell manufacturing in Europe 2. New sustainable electrode and cell manufacturing techniques with low energy consumption, and no Volatile Organic Compounds (VOCs) emissions 3. Electrode coating production techniques eliminate organic solvents reduce the capital costs associated to the solvent recovery system 4. Dry manufacturing techniques with next generation materials 5. Industrializing closed loops and process design to return low-value chemicals from manufacturing processes to high-value products.
In NoVOC we aim to design and demonstrate two competitive cell manufacturing technologies aqueous and dry cell manufacturing technologies for automotive batteries intended for production in Europe. The innovations proposed in NoVOC centre on improvements of cell manufacturing process by integrating two novel electrode manufacturing processes into the currently available cell assembly process and demonstrate manufacturability of automotive cells in two formats (pouch and cylindrical) with no toxic organic solvent at the fraction of the cell manufacturing cost that is currently available today. Next generation cell manufacturing processes developed in Europe for electric vehicles batteries
HiBRAIN
The HiBRAIN project is funded by the Federal Ministry of Economics and Climate Protection (BMWK) as part of the 7th Energy Research Program of the Federal Government "Innovations for the Energy Transition". In order to support the strategic goal of the energy transition in transport, the project focuses on the development of new cells for electrochemical energy storage. The HiBRAIN project involves representatives from material, electrode and automotive production as well as software developers, universities and research centers with expertise in battery materials, mathematical modeling and model-based (stochastic and numerical) simulation. The HiBRAIN project thus strengthens the link between basic research and industrial application with regard to suitable simulation methods to support electrode design.
The aim of the joint project is to develop an effective tool for the virtual design of new electrodes, based on the selection of suitable materials, the choice of microstructure (e.g. size and shape of primary and secondary particles), the additional coating of active particles and the structure and thickness of the electrodes. The challenge for the HiBRAIN project is to develop a holistic approach that also involves the use of artificial intelligence (AI) to optimize electrode design. The extensive database required for this shall be generated primarily by model-based simulations, which will be supported by specifically collected experimental data.
Within the framework of this project, CUSTOMCELLS® will primarily deal with the production of specifically tailored, performance-optimized electrodes and cells for the testing and validation of the developed simulation tool.
HELENA
CUSTOMCELLS® develops and scales a all-solid-state battery technology with an halide electrolyte up to a prototype cell production environment. To support the upcoming short-term needs of the battery industry, it is imperative to have new differentiating European battery technology for 4b generation batteries on the market from 2025. Halide solid state batteries for ELectric vEhicles aNd Aircrafts (HELENA) responds to the need of the development of a safe, novel high energy efficiency and power density solid state battery (4b generation batteries) cells, based on high capacity Ni-rich cathode (NMC), high-energy Li metal (LiM) anode and Li-ion superionic halide solid electrolyte for application in electric vehicles and, especially in aircrafts. HELENA will support Europe, in this sense, on its transition towards a climate-neutral continent since electric aviation is poised to take off within the next five to 10 years, with innovations already being pursued for electric vehicle batteries. Moreover, HELENA will avoid dependence on Asia for battery production. HELENA is built by a multidisciplinary and highly research experienced consortium that covers the whole battery value chain and proposes a disruptive halide-based solid-state cell technology with the overall aim to significantly increase the adoption of these batteries on aircrafts and EVs The technical challenges that are presented by current conventional battery technology and the consumer needs will be overcome - especially the reduction in costs of battery devices, enable scalable and safe cell manufacturing, increasing their capabilities for long distance traveling and fast charging, ensuring a high safety of the battery.
Funded by the European Union. Views and Opinions expressed are however those of the author(s) only and do not necessary reflect those of the European Union or Horizon Europe. Neither the European Union nor the granting authority can be held responsible for them.
ProLiT
With the aim of holistically developing dry coating for cathodes in lithium-ion batteries (LIB), the ProLiT cooperation project was launched on January 1, 2022. As part of the funding guideline "Battery materials for future electromobile, stationary and other industry-relevant applications (Battery 2020 Transfer)" in the framework program "from material to innovation" of the German Federal Ministry of Education and Research (BMBF), the project combines all the necessary expertise from industry and science. A hybrid approach couples LIB material development with process and plant development with the aim of transferring highly scalable and competitive processes and products to industry. Overall, the project opens up economic and ecological competitive advantages by eliminating the toxicologically critical N-methyl-2-pyrrolidone (NMP). This results in cost savings including energy for evaporation, dryer and building investment, and NMP recovery, as well as expensive occupational health and safety and explosion protection measures. Ecologically, the elimination of solvents promises high energy efficiency due to lower energy consumption of the streamlined process and the shorter process duration. Overall, the carbon footprint and economic efficiency of battery cell productions and thus the sustainability of electric cars and other mobile products could be increased. Material synthesis and development aims at adapting and optimizing LIB materials for the dry deposition process to realize the required electrode properties. This includes formulation development as well as understanding how the microstructure is formed and influenced, taking into account the framework conditions for solvent-free process control. Another unique selling point of the project is the process and equipment development of an efficient industrial process in terms of throughput in coupling with product development. This involves the reciprocal consideration of scalable mixing processes for material structuring discontinuously in the batch mixer and continuously in the extruder, continuous metering and powder handling, and the actual and multi-stage coating process in the specially adapted multi-roll calender. The identification of potentials with regard to the industrialization of the processing operations is always in focus. CUSTOMCELLS® is developing and evaluating processes for the dry coating of next generation electrodes. The focus will remain on production environments and dry slurry development.
BetterLiBs
The performance of lithium-ion batteries depends largely on the diffusion rate of the lithium ions in the electrolyte and the chemical stability (lithium storage capacity) of the electrode materials. If electrolytes with unfavourable properties are chosen, the storage capacity and service life of the cells can be severely limited. This leads, for example, to short ranges and frequent battery changes in electrically powered vehicles. In the development of high-performance cells, the (further) development of suitable electrolytes therefore also plays a decisive role. The aim of the BetterLiBs project is to improve the performance of lithium-ion batteries with liquid electrolytes by developing new types of electrolyte additives. The new fluorine-free additives are particularly characterised by their high sustainability and multifunctionality. Due to their zwitterionic properties, they increase the polarity and ionic conductivity of the electrolyte and are also thermally and electrochemically very stable. Furthermore, the additives enable protection of the electrode surfaces due to their polymerisability. The addition of the new additives is expected to reduce the production costs of lithium-ion batteries by up to 33% while significantly improving their cycle stability and energy density. CUSTOMCELLS® will test the effectiveness of the new electrolytes in pouch cells. For this purpose, demonstrator cells with different cell chemistries will be set up to investigate the compatibility and advantages of the new additives.
IntelLiGent
CUSTOMCELLS® develops and upscales electrodes and cell designs for next generation batteries (3B) based on Si-Gr/LMnO. The IntelLiGent project answers to the need for general public acceptance of EVs, by facilitating the industrial deployment of next-generation batteries allowing for an increased driving range, fast charging capabilities, low cost and increased safety.
Funded by the European Union. Views and Opinions expressed are however those of the author(s) only and do not necessary reflect those of the European Union or Horizon Europe. Neither the European Union nor the granting authority can be held responsible for them.
HighSpin
CUSTOMCELLS® develops the next generation (3b) of battery cells in the HighSpin project. HighSpin aims to develop high-performing, safe and sustainable generation 3b high-voltage spinel LNMO||Si/C material, cells and modules with a short industrialisation pathway and demonstrate their application for automotive and aeronautic transport applications. The project addresses in full the scope of the HORIZON-CL5-2021-D2-01-02 topic, setting its activities in the “high-voltage” line
Funded by the European Union. Views and Opinions expressed are however those of the author(s) only and do not necessary reflect those of the European Union or Horizon Europe. Neither the European Union nor the granting authority can be held responsible for them.
SOLIFLY
The SOLIFLY project has three vertical objectives. First, to explore and further develop a non-conventional formulation of a semi-solid Li-ion battery material suitable for structural batteries: NMC622 (cathode), Si/C (anode), and bicontinuous polymer ionic liquid electrolyte (BCE), i.e., NMC622|BCE|Si/C. Second: Enabling the functional integration of this material within CCF and RMS concepts, targeting the level of a representative aeronautical stiffened panel structure. Third, the SOLIFLY demonstrator aims to achieve a cell-level gravimetric energy density between 100 and 180 Wh/kg at a nominal discharge rate of 1C. The cell shall be capable of 300+ cycles at 0.1C with 90% capacity retention. Overall, the concept shall be at a TRL level of 4. CUSTOMCELLS® is creating an industrialization concept for this innovative technology in cooperation with the partners.
This project has received funding from the Clean Sky 2 Joint Undertaking (JU) under the European Union’s Horizon 2020 research and innovation programme under grant agreement No 101007577. The JU receives support from the European Union’s Horizon 2020 research and innovation programme and the Clean Sky 2 JU members other than the Union.
HiQ-Carb
Sustainable, high-quality carbon additives are essential to further enhance the performance of Li-ion batteries. In the HiQ Carb project, high-purity conductive additives and high-quality carbon nanotubes are being developed and manufactured by the leading European material manufacturers. The developed high quality carbon additives and carbon nanotubes will be used to manufacture the high energy and high performance cathodes. CUSTOMCELLS® will use the developed carbon additives and optimized recipes to scale up electrode manufacturing and produce pilot cells with high power density and high energy density, respectively.
RoSiLib
The aim of the project is to increase the silicon content of the anode up to 25 % - and thus significantly compared to the state of the art - by means of novel nanoporous silicon powders, which can be manufactured via a cost-effective, environmentally compatible (free of hydrofluoric acid) and easily scalable process. The project also aims to combine the newly developed anode with a commercially available next-generation cathode (high nickel content) to produce a large-format pouch cell. Computationally, this development is expected to increase the energy density above 350 Wh/kg and 1,000 Wh/l in pouch cells. CUSTOMCELLS® will participate in the anode paste development and battery cell production as part of the RoSiLiB project.
NeuroBATT
The NeuroBatt project aims to generate a database by systematically testing lithium-ion batteries with integrated optical sensors. By means of cyclic and calendrical aging tests as well as dynamic impedance spectroscopy, an AI-supported prognosis tool for the condition determination and lifetime prediction of electrical energy storage devices will be developed and evaluated. In the project, CUSTOMCELLS® is developing intelligent pouch cells that provide the data for the prognosis tool by integrating sensors. A particular challenge here is the direct integration of an optical fiber into the electrode coating of the cells, which will later provide data on local pressure and temperature differences in the cells via optical measurements, among other things. The AI-supported evaluation of this data makes it possible to optimize the operating strategies of electrochemical energy storage systems in order to limit aging effects or to detect them at an early stage.
InterBATT
In the InterBatt project, CUSTOMCELLS® is developing a new type of cell technology which, based on an "all solid state" concept, is to be projected onto the processes currently in use. To achieve this goal, systematic adjustments are being made to the manufacturing technologies. Anode materials and coated anode foils will be developed and further processed in cooperation with the partners. A cathode specially designed for the construction of test cells is to enable rapid market access for this technology after the end of the project. The electrochemical characteristics of the cells will be integrated into the evaluation of the market situation.
3beLiEVe
The 3beLiEVe project aims to strengthen the position of the European battery and automotive industry by delivering the next generation of battery cells, developed and manufactured in Europe, for the electric vehicle market. CUSTOMCELLS® focuses on the development of automotive battery cells with high performance (high energy density, fast charging capability, long lifetime) that are free of critical raw materials such as cobalt and natural graphite. In addition, the integration of sensors in and on the cells is being investigated. This should enable intelligent, adaptive operating strategies and advanced diagnostics to extend the useful life of the battery in applications.
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 875033.
Power400
The aim of CUSTOMCELLS® is to develop a battery technology installed in vehicles that enables rapid charging within a period comparable to a "classic refueling stop" of less than ten minutes. The disadvantages associated with fast charging processes in terms of battery life and safety are drastically reduced by this novel technology. In the Power400 project, CUSTOMCELLS® is working closely with research institutions and universities. This joint project is an important step towards decarbonizing the public transport system and thus towards climate protection.
BiSSFest
Through the development of solid-state batteries, improvements of conventional lithium-ion batteries can be achieved in several areas. By replacing the mostly flammable liquid electrolytes with solid lithium-ion conductors, the safety of the cells can be significantly increased. In addition, by using anode materials with high energy densities such as elemental lithium, cells with extremely high energy and power densities can be produced. In the BMBF-funded project "BiSSFest", solid-state batteries with sulphidic solid-state electrolyte and lithium anode are to be developed. This class of solid-state electrolytes is particularly characterised by high lithium ion conductivity and good processability. Starting with the (further) development of the materials, via their processing into electrodes and cells, up to the definition of the operating conditions of the batteries, all aspects of this new cell type will be illuminated. CUSTOMCELLS® will be responsible for the cell assembly and the characterisation of the sulphidic solid-state batteries within the framework of the project. Particular focus will be placed on investigating the necessary manufacturing and operating conditions of the cells. In addition, CUSTOMCELLS® will manufacture solid-state batteries under completely inert and dry room atmospheres and subsequently compare their performance. The work in the project can thus make an important contribution to the commercialisation of this new, promising battery technology.
ZIM-EXAMPLE OF SUCCESS: HIGH TEMPERATURE LITHIUM-ION BATTERIES
New Li-ion batteries meet the highest safety standards at temperatures up to 150 °C. Even under extreme application conditions, such as in deep geological drilling, they reliably supply energy for sensors and can be charged on site. The batteries are available for a variety of other applications. Conventional lithium-ion battery cells only guarantee safe use and an acceptable life expectancy within a limited temperature range (typically 0 °C to 40 °C, maximum 60 °C). Other energy storage systems such as lithium metal batteries allow higher application temperatures, such as those found in deep drilling, but at the same time have a high risk potential and are not rechargeable. When operating so-called MWD (Measurement While Drilling) devices, in which the measuring equipment is integrated into the drill string behind the drill rig, the sensors used must be supplied with energy. This is done by a generator in the drill head, which is driven by the drilling fluid, but does not provide the same power throughout. Therefore, batteries that can withstand the extreme conditions are needed as an energy buffer.
The product and its innovation
Stimulated by the need for MWD equipment to measure boreholes, CCUSTOMCELLS®, the Fraunhofer Institute for Silicon Technology (ISIT) and the Canadian company Evolution Engineering Inc. have set themselves the goal of developing lithium-ion batteries that are particularly safe and can be discharged and charged at high temperatures. This would eliminate the need to change the batteries that were previously necessary for drilling. In the ZIM cooperation project, ISIT has developed a concept for magnetic field-reduced cells in Li-Ion technology, while CUSTOMCELLS® concentrated on the development of high-temperature resistant battery cells based on a novel Li-Ion cell chemistry with new material combinations. The Canadian partner Evolution Engineering Inc. was responsible for assembling the cells into battery packs, adapting the battery management system and conducting field tests.
The market and customers
As a result of the development and production of the first sample series, CUSTOMCELLS® offers customer-specific configurable Li-ion battery cells that can be reliably charged and discharged in the temperature range from 0 °C to 150 °C, offer a high degree of safety against thermal penetration and metal fire and can be used with a long service life even under harsh environmental conditions. The market potential for high-temperature lithium-ion batteries is large. In addition to the already existing use in borehole measurements, there are many other possible applications. They are suitable as energy suppliers, for example, for the wireless energy supply of medical technology devices that are hot sterilised, for monitoring safety-relevant or particularly hazardous areas where high ambient temperatures can occur, or as energy back-up systems for actuators in safety-critical areas where high temperatures occur in the event of a disaster.
The cooperation partners
CUSTOMCELLS®, founded in 2012 as a spin-off from the Institute for Silicon Technology of the Fraunhofer Gesellschaft (ISIT), is one of the world's leading companies in the development of application-specific lithium-ion battery cells. The Fraunhofer ISIT in Itzehoe is one of the most modern research institutes for microelectronics and microsystems technology in Europe. In close cooperation with partners from industry, miniaturised components for power electronics and microsystems for sensor and actuator technology are developed here. For more than 20 years, research has also been conducted at ISIT on new Li accumulators. The Canadian company Evolution Engineering Inc. of Calgary (province of Alberta) participated in the cooperation project without ZIM funding. Founded in 2011, the company focuses its research and development on sensor-based solutions to various technical problems and is a specialist for MWD devices.
More information
COMPLETED FUNDING / RESEARCH PROJECTS
CUSTOMCELLS® has actively participated in a variety of funding and research projects.
KomVar
The KomVar funding project involves the development and establishment of series production of high-quality lithium-ion battery cells in small to medium volumes at the CUSTOMCELLS® site in Tübingen. The BMWi-funded project was officially approved on 01.09.2019 and, with a total volume of 8.2 million euros (4.7 million in funding) over 24 months, is pushing the development of competitive variant production for lithium batteries with a service character for lithium-ion cell development and for the production of small and medium series for niche markets. CUSTOMCELLS® will be involved in all work packages. Tasks in the project include support in planning and construction of the facilities as well as development and supply of electrode foils for the test production runs. Furthermore, CUSTOMCELLS® will also be involved in the quality tests on the cells.
MagSiMal
The collaborative project aims to demonstrate the performance of a new reversible energy storage technology based on magnesium and sulfur in an industry-compatible battery cell. The project follows on from the developments of the MagS project (2016-2018). The focus of MagSiMal is on the further development of all individual components of the magnesium-sulfur cell, but especially the anode and cathode active materials and the electrolyte. As a result, the capacity and cycle stability of the magnesium-sulfur cells are to be increased to 400 mAh/g(sulfur) and 40 cycles. In the project, CUSTOMCELLS® is developing concepts for processing and handling the novel cell components. Due to the improved moisture and oxygen resistant active materials, cell assembly can be performed in a manufacturing environment similar to lithium-ion cells. CUSTOMCELLS® manufactures and characterizes magnesium-sulfur cells in various cell formats up to VDA format (BEV1) to further advance the commercialization of this technology.
LiSiWi
The goal of this collaborative project is to develop and implement high capacity anodes for Li-ion cells. This will be achieved by using composites of a novel active material, Si nanowires (Si-NW) and graphite, as anode active material. The work will be carried out in collaboration with materials specialist ENWIRES. CUSTOMCELLS® will use its own flexible electrode fabrication line to contribute to the research of suitable electrode recipes. The resulting electrode will be applied in pilot cells, and the appropriate test protocols will also be investigated and applied.
Fab4Lib
The Fab4Lib project was funded by the German Federal Ministry of Education and Research under grant number 03XP0142. The project aimed to research innovative solutions along the value chain of lithium-ion technology and to validate them in demonstrators, thus laying the foundation for the establishment of large-scale production of lithium-ion cells in Europe. In eleven work packages, the collaborative partners with CUSTOMCELLS® focused on topics such as energy-autonomous infrastructure, cell design, innovative production processes and materials, Industry 4.0 or recycling strategies. At the end of the project, a competitive production unit with a production capacity of approximately 6 GWh p.a. was developed. In the future, the unit can be built up modularly and many times where the corresponding capacity is needed.
Chits
New Li-ion batteries meet the highest safety standards at temperatures up to 150 °C. Even under extreme application conditions, such as in deep geological drilling, they reliably supply energy for sensors and can be recharged on site. In the CHITS project, rechargeable lithium-ion cells suitable for an extended temperature range were developed. In the ZIM cooperation project, ISIT had developed a concept for magnetic field reduced cells in Li-ion technology, while CUSTOMCELLS® focuses on the development of the high temperature resistant battery cells based on a novel Li-ion cell chemistry with new material combinations.
ECO:COMBAT
The goal of the ECO COM'BAT project was to combine and scale up the combination of the most ecological and high performance materials possible for the next generation of high volt Li-Ion batteries. The production of an ORMOCER® coated NMC 622 and the lithium salt LiFSI were scaled up to batch sizes of about 10 - 20 kg. In addition, improvements in energy and power density were investigated using the structured carbon additives Porocarb® and Graphistrength®. CUSTOMCELLS® developed pilot cells from these novel and sustainable materials that showed improved performance compared to cells with industrial reference samples.
MagS
In the joint project MagS, the high potential for magnesium-sulfur batteries with high capacities at greatly reduced costs was demonstrated. In practice, however, there are still many challenges with the sulfur cathode, the high overpotential of the magnesium anode and the development of a suitable electrolyte system. Together with the project partners, CUSTOMCELLS® has successfully implemented the goal of developing magnesium-sulfur battery cells within a pouch-bag in a larger VDA format and manufacturing them within a pilot production. Within the MagS project, experimental investigations and theoretical studies were also carried out in order to achieve a better understanding of the mechanism of the magnesium-sulfur battery and thus an improved performance.
SiGgl
In the joint project SiGgI, CUSTOMCELLS® successfully demonstrated the transition of silicon (Si) carbon (C) composite technology from laboratory to industrial scale. The project included material development of silicon-carbon composites, comminution of Si/C milling beads to nanometer scale, and electrochemical surface treatment of silicon anodes. A process for pilot-scale fabrication of silicon-carbon electrodes was also developed. CUSTOMCELLS® was responsible for the fabrication of the demonstrator and the necessary scale-up of the Si-C electrode fabrication.
BeBAT
How can lithium-ion batteries be manufactured more sustainably? In answering this question, the binders used in the electrodes also play an important role. They should be harmless to health and, in the spirit of the bioeconomy, contain as high a bio-based content as possible. In a research project funded by the German Federal Ministry of Food and Agriculture (BMEL) through the Agency for Renewable Resources (FNR), the Technical University of Braunschweig, the Thünen Institute and CUSTOMCELLS®, as well as Schill + Seilacher "Struktol" as an associated partner, tested the suitability of bio-based epoxy hardener systems as a substitute for the common petrochemical and halogenated binders.
CUSTOMCELLS® RESEARCH PARTNER
YOUR CONTACT FOR RESEARCH PROJECTS
Dr. Sebastian Willrodt
Funded Projects
CUSTOMCELLS Itzehoe
Fraunhoferstr. 1b
25524 Itzehoe
