Process Optimization How Cost-Effective And Sustainable Batteries Become Reality

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Fraunhofer IWS Dresden

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

However, producing high-performance batteries at a low price is a major challenge. The Drytraec technology from the Fraunhofer Institute for Material and Beam Technology IWS in Dresden (Germany) aims to address this problem with a novel approach. Typically, battery electrodes are produced using the wet process. In this method, a mixture known as slurry, consisting of active material, conductive carbon black, binders, and solvents, is applied to metal foils and then dried. This process consumes a lot of energy, burdens the environment, and incurs high costs.

The Dry Path to the Electrode

With Drytraec, Fraunhofer IWS has developed a process that completely eliminates the need for 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 calendaring device generates shear forces that bind the particles together, forming a stable electrode layer. This eliminates the need for energy—and space-intensive drying. A great side effect: the double-sided coating of the electrodes is simplified and accelerates the production process, as both occur in a single step.

Normally, new methods come with many new disadvantages. They are often expensive, hard to integrate, or technically immature. Not so with Drytraec: Here, innovation meets real practical applicability.

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 its so-called "drop-in capability," Drytraec can be directly integrated into existing production lines without the need for extensive retrofitting.

From Idea to Industrial Application

The first prototype plant was established as early as 2013. Since then, the process has been continuously developed. Today, Fraunhofer IWS operates a comprehensive R&D platform that supports industry partners from the first test to technology transfer. The licensing to a leading European automotive 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 Joseph von Fraunhofer Prize 2025. The award recognizes the relevance of this technology for resource-efficient and economical battery cell production. Drytraec sets new standards—and significantly strengthens the future of Germany as an automotive location. (mr)

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