Revolutionizing Electric Vehicle Batteries: The Development of Sustainable, Low-Cost Production Technologies

Energy Transition — Sustainable, Low-Cost Batteries for the Electric Vehicles of Tomorrow
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Electric mobility is advancing rapidly in Germany and across Europe. To maintain this momentum, there is a critical need for an extensive expansion of battery cell production capacity within the country. Additionally, production methods must be energy-efficient and cost-effective.

A team of researchers from the Fraunhofer Institute for Material and Beam Technology IWS in Dresden has introduced **DRYtraec**, a groundbreaking method for the cost-effective and eco-friendly manufacturing of battery electrodes. This innovative technology earned them the **Joseph von Fraunhofer Prize for 2025** during the Fraunhofer annual assembly.

Using the new **DRYtraec dry transfer technology**, electrodes for energy storage cells are coated with a dry film instead of traditional liquid chemicals. As electrified vehicles and stationary energy storage become increasingly vital for a climate-neutral energy sector, sustainable production of lithium-ion batteries is essential. Led by researchers **Benjamin Schumm, Holger Althues,** and **Stefan Kaskel**, the DRYtraec method eliminates the use of toxic solvents and removes the energy-intensive and costly drying process typically required for electrode layers.

A critical component of any battery, the electrodes usually consist of a metal foil with a thin coating containing active materials for energy storage. Schumm, head of the Particle Technology department at Fraunhofer IWS, explains, “The conventional coating process applies a wet chemical method known as slurry. The DRYtraec technology allows us to produce an electrode layer directly from a dry mixture of active material, conductive carbon black, and binders.” Unlike the conventional slurry method, this process does not require solvents. Instead, a specialized calender unit generates shear forces in a roller gap, mechanically anchoring the particles of active material and conductive carbon black by creating fibrils in the binder—a process known as fibrillation. This results in a completely dry electrode layer, effectively eliminating the need for the energy-intensive drying stage, which also occupies considerable space.

Furthermore, the **DRYtraec** method enables double-sided coating of the electrodes in a single step by directly transferring both sides to the current collector foil. The solvent-free DRYtraec electrodes exhibit exceptional performance and stability, without the drawbacks associated with slurry-based electrodes.

This patented technology holds immense potential for the future. The roller-based dry film transfer process minimizes production risks and facilitates scaling up to larger coating widths and higher processing speeds. The world’s first prototype system was designed and built back in 2013, and the technology has been progressively refined since then. The system allows for continuous process control and the production of high-quality electrodes in a roll-to-roll process. Althues, head of the Battery Materials department at Fraunhofer IWS, states, “For DRYtraec, we have established an R&D platform that offers industry customers a wide range of options—from testing to transfer to commercial use—throughout the value chain. Having licensed the technology to a leading company in the European automotive sector, we are now well-positioned for further scaling to mass production.”

The DRYtraec method is also adaptable for emerging battery technologies, such as sodium-ion and solid-state batteries. “We have demonstrated ‘drop-in’ capability for electrode production with these systems,” explains Kaskel, Technology Field Manager for Battery Technology at Fraunhofer IWS. “Initially developed for lithium-ion batteries, we have since tailored the process for lithium-sulfur and solid-state batteries. These technologies will gain importance in the future, but their performance often suffers with wet chemical processing. DRYtraec provides a promising alternative with significant advantages.”

The patented DRYtraec technology, now recognized as a standard method of dry coating, reinforces Fraunhofer IWS’s position as a leading R&D provider in this field. This development plays a crucial role in maintaining Germany’s status as a hub for automotive production and highlights the importance of production technology as a key driver of value creation in the mobility transformation.