Fraunhofer Research Institution for Battery Cell Production FFB 
FELKON
Research Project, “FELKON - Error Detection, Machine Learning, and Correlation for Sustainability”
The development of innovative digital and imaging technologies for battery cell defect inspection by companies in North Rhine-Westphalia makes a lasting contribution to strengthening Germany and Europe as business locations. The technologies being pursued by the consortium have the potential to make battery cell manufacturing more competitive and sustainable even in high-wage countries like Germany by reducing scrap. The participation of the Fraunhofer Institute “Battery Cell Research and Production” (FFB) in Münster in the targeted introduction of defects promotes both the expansion of domestic battery cell production and a reduction in material consumption through lower production scrap. Through long-term cycling of battery cells, the project also investigates which defects disproportionately affect performance over the life cycle and how these can be detected early on. This reduces dependence on third countries that currently play a dominant role in battery technology.
Work Plan
The project is structured into six interlinked work packages:
WP1 covers project management and knowledge transfer, ensuring consortium coordination, progress monitoring, reporting, and the dissemination of results.
WP2 focuses on preparation, including the extension of the defect catalogue, the refinement of the grading system, and the definition and recording of relevant process parameters.
WP3 establishes the technical basis for defect recording and program development, including the validation of process data acquisition, the development of ML/AI models, and initial production runs to verify both data capture and model performance.
WP4 addresses defect tracking and analysis throughout the production process in order to systematically understand the origin, evolution, and amplification of defects.
WP5 links the recorded process and optical data with graded battery quality, evaluates their impact on electrochemical performance, and validates optimization measures through targeted production runs.
WP6 adds a lifetime analysis through standardized battery cell cycling in order to assess the long-term impact of specific defects on ageing and performance.
Exploitation of Results
The FELKON project will generate key insights into which defects arise during electrode manufacturing, how these defects evolve across process steps, and which defect types have the strongest impact on the electrochemical performance and lifetime of battery cells. The main results will include an expanded and standardised defect catalogue, an improved grading system, a robust database combining image, process, and performance data, AI-based methods for automatic defect detection and classification, and validated correlations between defect classes, process parameters, cell quality, and ageing behaviour. In addition, the project will deliver optimised production parameters and validated production runs that help reduce scrap, improve quality, and increase the sustainability of battery cell manufacturing. Exploitation is planned through the direct transfer of results into industrial applications, follow-up research and development activities, and broad dissemination via conferences, trade fairs, open-access publications, training seminars, and academic teaching. The developed methods are also transferable to other cell types, battery materials, and future research and industrial projects.
