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Battery Manufacturing: Current Status, Challenges, and Opportunities: 2nd Edition
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Battery Manufacturing: Current Status, Challenges, and Opportunities: 2nd Edition

A special issue of Batteries (ISSN 2313-0105). This special issue belongs to the section "Sustainable Manufacturing and Circular Economy".

Deadline for manuscript submissions: 20 August 2026 | Viewed by 6972

Editor

Dr. Kamil Burak Dermenci

E-Mail Website
Guest Editor
Electromobility Research Centre (MOBI), Vrije Universiteit Brussel, Pleinlaan 2, 1050 Brussels, Belgium
Interests: lithium-ion battery manufacturing; solid-state Li-ion battery; Ag/ZnO nanocomposite particles; material characterization; materials; nanomaterials; nanomaterials synthesis; materials processing; nanostructured materials; nanoparticle synthesis; ceramics; ceramic materials; battery
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

As an increasing number of battery (giga)factories continue to be constructed on a global scale, there is a growing interest in battery manufacturing processes, and this increase in battery manufacturing will pave the way for electrification in the future. A reliable, low-cost, best-performing, and secure value chain is envisioned for battery manufacturing processes by 2040 and beyond.

For this Special Issue, we are seeking contributions that address current challenges, with a particular focus on cell assembly and manufacturing methodologies with a chemistry-neutral approach, as well as the latest advances in battery materials that enable increases in large-scale battery performance, scaled-up cell manufacturing, smart manufacturing methodologies and/or novel battery machineries in lithium and post-lithium systems. Research on the use of Industry 4.0 tools in cell manufacturing, such as 3D printing, is also highly encouraged.

Experimental and/or theoretical contributions to lab-scale or pilot-scale research, with a particular focus on novel battery manufacturing routes, are also welcomed. Therefore, submissions focusing solely on material development will be considered out of scope. Sustainable and safe processing during battery recycling is also considered a valuable topic for this Special Issue. Contributions on the processing, design, and valorization of active materials, and efficient recovery of battery components are also welcomed. However, theoretical work without experimental validation will be considered out of scope. 

Dr. Kamil Burak Dermenci
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-anonymized peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Batteries is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • battery manufacturing
  • smart manufacturing
  • digitalization
  • Industry 4.0
  • electrodes
  • electrolytes
  • end-of-life batteries
  • recycling
  • recovery

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Related Special Issue

Published Papers (5 papers)

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Research

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22 pages, 5876 KB  
Article
Continuous Mixing of Graphite Anode Slurry: Fast-Charge Optimization Through Binder Network Tailoring
by Paul Guenther, Andreas Huth, Kristian Nikolowski, Oliver Lohrberg, Mareike Partsch, Annegret Potthoff and Alexander Michaelis
Batteries 2026, 12(7), 261; https://doi.org/10.3390/batteries12070261 - 18 Jul 2026
Viewed by 125
Abstract
Fast-charging lithium-ion batteries require graphite anodes with low ionic transport resistance, yet systematic links between electrode manufacturing parameters and fast-charge performance remain scarce. This study shows that twin-screw extrusion (TSE) process conditions control electrode tortuosity, the geometric complexity of ionic pathways, by reshaping [...] Read more.
Fast-charging lithium-ion batteries require graphite anodes with low ionic transport resistance, yet systematic links between electrode manufacturing parameters and fast-charge performance remain scarce. This study shows that twin-screw extrusion (TSE) process conditions control electrode tortuosity, the geometric complexity of ionic pathways, by reshaping the binder network architecture without altering active material integrity. A central composite experimental design combined with multi-scale diagnostics identifies pore network tortuosity as the primary transport bottleneck. The optimized mild kneading condition (K4: 60 wt% kneading zone solids, 7% kneading length, gentle screw design) reduces the 8–80% state-of-charge (SOC) charging time by 14.9% relative to the intensive baseline (B1–B3: 70 wt%, 50% kneading length), matching conventional batch mixing. Regression analysis confirms a strong correlation between tortuosity and fast-charge performance (R2=0.86), whereas the correlation with charge-transfer resistance is weaker (R2=0.59). Mechanistically, mild kneading promotes reversible, sterically stabilized carboxymethyl cellulose (CMC) networks consistent with extended “loop-tail” polymer conformations. Intensive kneading is consistent with the formation of bridging gels that fail to arrest binder migration during drying and clog surface pores. A Pore-Homogeneity Index (PHI), derived from mercury porosimetry, quantifies the resulting microstructural heterogeneity, correlates with tortuosity (R2=0.76), and characterizes pore network uniformity. The results identify local stress intensity as a primary factor influencing binder network formation and support tortuosity as an adjustable design parameter in continuous anode processing. Full article
(This article belongs to the Special Issue Battery Manufacturing: Current Status, Challenges, and Opportunities: 2nd Edition)
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18 pages, 778 KB  
Article
A Survey-Informed Digital Competitiveness Framework for Emerging Battery Manufacturing Ecosystems: Evidence from Romanian Cross-Sectoral Industrial Firms
by Mirela Simijdean, Diana Ilea, Denisa Szabo, Ovidiu Aurel Ghiuță, Aurel Mihail Țîțu and Mihai Dragomir
Batteries 2026, 12(7), 257; https://doi.org/10.3390/batteries12070257 - 17 Jul 2026
Viewed by 189
Abstract
The article proposes an exploratory approach that combines literature-based analysis of digital transformation and competitiveness in battery manufacturing ecosystems with survey evidence collected from Romanian companies operating in technology-related sectors. The empirical approach described provides indirect ecosystem-level evidence from Romanian firms potentially relevant [...] Read more.
The article proposes an exploratory approach that combines literature-based analysis of digital transformation and competitiveness in battery manufacturing ecosystems with survey evidence collected from Romanian companies operating in technology-related sectors. The empirical approach described provides indirect ecosystem-level evidence from Romanian firms potentially relevant to future battery value chains, as full-fledged manufacturers only now entering the strategic horizon. The study is founded on the need for companies to achieve a consistent and committed transformation that goes beyond adopting and integrating various digital technologies, reaching aspects related to production facilities, human–machine integration, and smart governance approaches. The objective of the research is to study the mutual impacts between facilities and processes on one hand, and technology on the other hand, in achieving competitiveness and sustainability for battery manufacturing ecosystems. In this regard, the paper investigates organizational capabilities, workforce adaptability, and digital technology deployment as enabling factors for a successful digital transformation. The results point to an improvement potential that may contribute to the resilience of the emerging battery industry under challenging conditions, while preparing for sector expansion brought about by developing electromobility and renewable energy options. The framework developed customizes general digital transformation capabilities into battery-manufacturing-specific requirements such as traceability, circularity, regulatory readiness, user safety, and ecosystem interconnectivity. Full article
(This article belongs to the Special Issue Battery Manufacturing: Current Status, Challenges, and Opportunities: 2nd Edition)
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Review

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23 pages, 970 KB  
Review
Rechargeable Batteries for Grid-Scale Energy Storage: Technologies, Performance, and Emerging Directions
by Lincoln Pinoski, Blake Latos, Devin Marigny, Taylor Jensen, Aidan De Los Reyes, Brian Helwig and Pradeep L. Menezes
Batteries 2026, 12(7), 264; https://doi.org/10.3390/batteries12070264 - 20 Jul 2026
Viewed by 251
Abstract
The accelerating transition toward renewable electricity generation has elevated grid-scale electrochemical energy storage from an ancillary grid service to a foundational infrastructure requirement. This review provides a comprehensive account of rechargeable battery technologies for stationary grid applications, spanning advanced lithium-ion systems, sodium-ion and [...] Read more.
The accelerating transition toward renewable electricity generation has elevated grid-scale electrochemical energy storage from an ancillary grid service to a foundational infrastructure requirement. This review provides a comprehensive account of rechargeable battery technologies for stationary grid applications, spanning advanced lithium-ion systems, sodium-ion and post-lithium multivalent chemistries, vanadium and organic flow batteries, solid-state architectures, and high-energy-density future systems such as lithium-sulfur and metal-air cells. The techno-economic context of grid-scale storage is systematically examined, including performance metrics, market drivers, and regulatory frameworks. Each battery chemistry is analyzed with respect to electrochemical mechanism, cycle life, energy density, safety profile, material availability, and commercial readiness. Non-electrochemical storage technologies are discussed as system-level alternatives. Battery safety engineering, thermal management system design, thermal runaway mechanisms and prevention, and failure containment strategies are examined in depth, followed by analysis of critical material supply-chain vulnerabilities, life-cycle assessment, and recycling pathways. The expanding role of artificial intelligence, machine learning, and digital twin frameworks in optimizing performance and enabling predictive maintenance is reviewed. Key challenges, including material bottlenecks, manufacturing scalability, long-duration storage gaps, and the absence of harmonized performance standards, are identified, and the review concludes with a techno-economic roadmap toward cost-competitive, resilient, and low-carbon grid storage. Full article
(This article belongs to the Special Issue Battery Manufacturing: Current Status, Challenges, and Opportunities: 2nd Edition)
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35 pages, 1400 KB  
Review
Sodium-Ion Batteries: Materials, Performance, and Application in Engineering Systems
by Subin Antony Jose, Blake Latos, Alvaro Hurtado, Jaylen Hurtado, Jacob Jenkins and Pradeep L. Menezes
Batteries 2026, 12(5), 180; https://doi.org/10.3390/batteries12050180 - 20 May 2026
Cited by 2 | Viewed by 1206
Abstract
Sodium-ion batteries (SIBs) are emerging as a viable alternative to lithium-ion batteries (LIBs) due to their material sustainability and cost-effectiveness, helping address the high costs, supply limits, and environmental concerns associated with lithium. This paper reviews SIB materials, designs, and applications, and surveys [...] Read more.
Sodium-ion batteries (SIBs) are emerging as a viable alternative to lithium-ion batteries (LIBs) due to their material sustainability and cost-effectiveness, helping address the high costs, supply limits, and environmental concerns associated with lithium. This paper reviews SIB materials, designs, and applications, and surveys their electrochemical performance, challenges, and future prospects. Recent advances in electrode materials (e.g., layered oxides, hard carbon composites, metallic alloys) are greatly improving SIB stability, conductivity, capacity, and cycle life. Improvements in both solid-state and liquid electrolytes have likewise enhanced ionic conductivity, capacity retention, thermal stability, and safety. Despite their lower energy density, SIBs tolerate wider temperature ranges and carry a significantly lower risk of thermal runaway compared to lithium-based systems, making them attractive for industrial, transportation, and large-scale power storage. Continuous progress in materials and cell engineering is narrowing the performance gap between SIBs and LIBs. Meanwhile, nascent battery recycling strategies for SIBs show promise for economic and environmental viability. Overall, SIBs represent a promising option for safer, more accessible, and more sustainable energy storage technology. Full article
(This article belongs to the Special Issue Battery Manufacturing: Current Status, Challenges, and Opportunities: 2nd Edition)
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28 pages, 2709 KB  
Review
Review of Direct Lithium Extraction Methods: Recent Advances and Outlook
by Olukayode Fatoki, Santosh Kumar Parupelli, Manpreet Kaur, Alex Mathew, Amir Rehmat and Salil Desai
Batteries 2026, 12(4), 133; https://doi.org/10.3390/batteries12040133 - 12 Apr 2026
Cited by 2 | Viewed by 4565
Abstract
Lithium-ion batteries (LIBs) have become the prominent energy storage technology because of their high specific energy, longer lifespan, and excellent efficiency. Traditional lithium extraction processes are energy intensive and time-consuming. Direct lithium extraction (DLE) methods provide a more sustainable and efficient alternative. This [...] Read more.
Lithium-ion batteries (LIBs) have become the prominent energy storage technology because of their high specific energy, longer lifespan, and excellent efficiency. Traditional lithium extraction processes are energy intensive and time-consuming. Direct lithium extraction (DLE) methods provide a more sustainable and efficient alternative. This review offers a comprehensive overview of lithium-ion battery resources and direct lithium extraction methods. The detailed discussion of the DLE methods, which include adsorption, ion exchange, solvent extraction, membranes separation, and electro-chemical systems is presented. A comprehensive analysis of the recent technological advances of the direct lithium extraction processes in terms of technology readiness levels, and commercial potential is reported. The advantages and the technical challenges of the DLE methods are also reported. Finally, the review outlines the artificial intelligence outlook of the DLE processes. The review aims to provide deeper insights into the limitations and the opportunities of DLE methods towards crucial future research efforts for lithium-ion batteries advancements. Full article
(This article belongs to the Special Issue Battery Manufacturing: Current Status, Challenges, and Opportunities: 2nd Edition)
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