Publicly-funded research projects

In the »FELKON« project, innovative digital and imaging technologies are being developed for the early detection of defects in battery cells. The aim is to reduce production scrap and material consumption, improve the quality and lifetime of battery cells, and thereby strengthen competitive and sustainable battery cell manufacturing in Germany and Europe.

In the »NRW-DiRecLab« project, the Fraunhofer FFB (Münster) and PEM (RWTH Aachen University) are establishing a research infrastructure – unique in Germany and Europe – for the direct recycling of electrode scrap from battery cell production. PEM will host a modular, flexible laboratory-scale environment, while Fraunhofer FFB will set up a scaled pilot-scale process route (vacuum comminution, supercritical CO₂ extraction, vibrating screen) plus complementary analytics and cell testing infrastructure. Five promising process routes with different delamination methods – thermal, solvent-based (optionally ultrasound-assisted), mechanical and scCO₂-based – will be investigated. The goal is to recover high-quality active materials, reintegrate them into cell manufacturing and thus close local material loops.

The “HEPAD” project is developing a highly efficient transport drone with a performance-optimized powertrain and innovative battery architecture. The goal is to significantly increase range, flight time, payload, and efficiency for inner-city and short-distance logistics applications.

The “InnoAktiv” project is developing and testing innovative materials, processes, and equipment technologies to accelerate cell activation in lithium-ion batteries. The focus is on significantly reducing activation time as well as lowering energy consumption, costs, and emissions.

The “SmartBMS” project is developing and validating innovative methods for optimizing battery management systems for lithium-ion batteries. The goal is to increase production and operational efficiency, reduce scrap, and improve the performance and service life of battery systems.

The FAiL project systematically investigates and evaluates safety-critical failure patterns in the production of lithium-ion battery cells. The focus is on the targeted creation of defects, their analysis using X-ray CT and high-speed radioscopy, and the development of digital methods for cell defect diagnosis. The goal is the early detection of safety-relevant cell defects, the improvement of quality assurance, and the enhancement of safety in battery cell production.

The DeKIBat project is developing innovative quality control methods for the manufacture of electrodes for lithium-ion batteries. The focus is on AI-based detection of surface and volume defects. The goal is to reduce scrap and improve product quality in battery cell production.

Even the smallest particles can have a huge impact on battery cell manufacturing: they affect cell performance and, in extreme cases, can lead to thermal runaway. In the “SiPaFeb” research project, we are developing an inline detection system that monitors particle contamination on the production line in real time and issues early warnings of critical conditions based on the collected process data.

The OnBASYS project is developing a safe and efficient battery storage system based on sodium-ion cells. This technology offers a sustainable alternative to conventional batteries, as the raw materials are more readily available and the fire risk is lower. In addition, the project is developing innovative solutions to further improve performance and safety.

As part of the TIME research project, we are working with our partners to develop smart measurement technology that monitors production processes in real time. Using artificial intelligence and advanced laser technology, defects can be detected early on and material properties can be analyzed with precision. The goal is to integrate this solution directly into an industrial pilot plant, thereby sustainably improving the quality and efficiency of electrode manufacturing.