Solid-State Chemistry for High-Energy Cells

AnSiLiS: Materials development, simulation and cell integration

The AnSiLiS project focuses on developing a sulfur-carbon composite cathode. This will be examined in combination with a thin lithium-metal anode and a hybrid electrolyte system in minimal quantity. TU Dresden and the University of Jena explore the electrochemical interactions between the electrolyte and active materials. Helmholtz-Zentrum Berlin contributes expertise in operando analytics and 3D tomography. Molecular dynamics simulations support the cell development process, enabling precise evaluations of component stability and compatibility on different scales.

Scaling and industrial validation

The EU project Talissman adds industrial scaling and application validation to the research. Coordinated by the Basque institute Cidetec, nine partners from Spain, France, Italy and Germany are developing two cell generations for electric mobility applications. Their targets include energy densities of up to 550 watt-hours per kilogram, the integration of non-flammable quasi-solid electrolytes and production costs of under 75 euros per kilowatt-hour. The cell design will remain compatible with existing lithium-ion battery production lines.

Integrating new materials and processes into prototype battery cells

In both AnSiLiS and Talissman, Fraunhofer IWS serves as the systems-integrating development partner. Basic chemical understanding, material expertise, process know-how and near-industrial pilot-scale manufacturing go hand in hand.

Research begins with the tailored formulation of powders, slurries and dry mixtures for different electrode manufacturing techniques. The proprietary DRYtraec technology by Fraunhofer IWS plays a central role. This solvent-free dry coating method presses materials into stable films without a drying step. It cuts energy use by up to 30 %, significantly reduces CO₂ emissions and scales to industrial widths via roll-to-roll processing. DRYtraec provides a viable route to bring innovative materials into mass production.

All production steps take place at the institute’s Advanced Battery Technology Center (ABTC) in Dresden. This facility features a flexible line for electrode manufacturing, utilizing classic slurry coating or DRYtraec, as well as laser cutting in dry air, multilayer stacking, thermal sealing and formation, with the option for cyclic aging. Combined with analytics and process simulation, this setup enables end-to-end cell development from a single source of origin. Fraunhofer IWS delivers more than lab-scale results – it provides near-application demonstrators. All cells undergo comprehensive electrochemical characterization. Industry partners from aerospace, drone technology and electromobility benefit from reduced development risk, accelerated technology transfer and economically viable battery production. Energy densities above 600 watt-hours per kilogram and specific costs below 75 euros per kilowatt-hour are within reach.

Target applications

Aviation, unmanned aerial systems and portable energy storage systems demand excellent energy-to-weight ratios. The cell concepts under development in AnSiLiS and Talissman directly address these requirements. The combination of optimized materials, in-depth analysis and process-driven development will pave the way for lithium-sulfur batteries in applications where conventional technologies reach their limits. Functional prototypes are expected to validate the projected performance in the coming years.

(Source: Fraunhofer IWS)