How cost-effective and sustainable batteries become a reality

Process Optimization How Cost-Effective and Sustainable Batteries Become a Reality

2025-07-03 From Dipl.-Ing. (FH) Michael Richter | Translated by AI 2 min Reading Time

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Building batteries with high performance is one thing. Producing them cost-effectively is another. To achieve this, an optimized process is usually required.

With the new Drytraec dry transfer technology, electrodes of energy storage cells are coated with a dry film instead of liquid chemicals.(Image: Fraunhofer / Piotr Banczerowski) — With the new Drytraec dry transfer technology, electrodes of energy storage cells are coated with a dry film instead of liquid chemicals.
(Image: Fraunhofer / Piotr Banczerowski)

However, the production of batteries with high performance and at the same time low cost is a major challenge. The Drytraec technology of the Fraunhofer Institute for Material and Beam Technology IWS in Dresden aims to address this problem with a novel approach. Usually, battery electrodes are produced using the wet process. In this process, a mixture called slurry, consisting of active material, conductive carbon black, binders, and solvents, is applied to metal foils and then dried. This process requires a lot of energy, burdens the environment, and incurs high costs.

The Dry Path to the Electrode

With Drytraec, the Fraunhofer IWS has developed a process that completely eliminates the use of solvents. Instead of the slurry mixture, a dry powder mixture of active material, conductive carbon black, and binder is mechanically applied to the current collector foil. A specially developed calender device generates shear forces that bond the particles together and form a stable electrode layer. This eliminates the energy- and space-intensive drying process. A great side effect: the double-sided coating of the electrodes simplifies and accelerates the production process, as both sides are coated in one step.

Normally, new methods come with many new disadvantages. They are often expensive, difficult to integrate, or technically immature. It's different with Drytraec: Here, innovation meets true practicality.

Sustainability and Scalability in Focus

The Drytraec technology completely eliminates toxic solvents—not only protecting the environment but also reducing energy consumption and production costs. The process is also scalable and flexibly applicable: it is suitable for lithium-ion, lithium-sulfur, and solid-state batteries. Thanks to the so-called "drop-in capability," Drytraec can be directly integrated into existing production lines without requiring extensive modifications.

From the Idea to Industrial Application

The first prototype system was developed in 2013. Since then, the process has been continuously refined. Today, the Fraunhofer IWS operates an extensive R&D platform that supports industry partners from the initial test to technology transfer. The licensing to a leading European automobile manufacturer now marks the next milestone: preparation for industrial mass production.

Recognition for Excellent Research

For their work on Drytraec, Dr. Benjamin Schumm, Dr. Holger Althues, and Prof. Dr. Stefan Kaskel were awarded the 2025 Joseph von Fraunhofer Prize. The award recognizes the significance of this technology for resource-efficient and economical battery cell production. Drytraec sets new standards—and decisively strengthens the future of Germany as an automotive hub. (mr)

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Date: 08.12.2025

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