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Batteries
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Battery Manufacturing: Current Status, Challenges, and Opportunities
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Battery Manufacturing: Current Status, Challenges, and Opportunities

A Special Issue of Batteries (ISSN 2313-0105) belonging to the section "Battery Processing, Manufacturing and Recycling".

Deadline for manuscript submissions: closed (15 August 2025) | Viewed by 19699

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,

There is a growing interest on battery manufacturing processes as more and more battery (giga)factories are to be built all over the world in the near future. Such a high battery manufacturing portfolio will definitely pave the way for electrification of future. A reliable, low-cost, best performant and secured value chain are envisioned in the battery manufacturing processes towards 2040 and beyond.

In this Special Issue, we are looking for contributions addressing the challenges with a particular focus on cell assembly & manufacturing methodologies with a chemistry-neutral approach. Latest advances on battery materials allowing to boost large-scale battery performance, scale-up cell manufacturing, smart manufacturing methodologies and/or novel battery machineries in lithium and post lithium systems are highly encouraged. Industry 4.0 tools during cell manufacturing such as 3D printing are also highly welcome.

Experimental and\or theoretical contributions are welcome in lab-scale or pilot-scale research with a particular focus on novel battery manufacturing routes. Therefore, submissions focusing only material development will be considered out of scope. Sustainable and safe processing during battery recycling is also considered a valuable contribution to the Special Issue. Processing, design and valorization of active materials, and efficient recovery of battery components are welcome. 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

19 pages, 2112 KB  
Article
Electrochemical and Post-Mortem Study of Pyrrolinium-Based Ionic Liquid on a Single-Layer Pouch Cell
by Pradeep Kumar Dammala, Javier García-Alonso, David Maestre, Kamil Burak Dermenci, Bianchi Méndez, Joeri Van Mierlo and Maitane Berecibar
Batteries 2025, 11(11), 428; https://doi.org/10.3390/batteries11110428 - 20 Nov 2025
Viewed by 1688
Abstract
Ionic liquid (IL)-based electrolytes have garnered significant interest for enhancing lithium-ion battery (LIB) safety due to their non-flammability, thermal stability, high conductivity, and broad electrochemical stability. We propose novel pyrrolinium-based ionic liquids to enhance lithium-ion mobility and address safety concerns in LIBs. This [...] Read more.
Ionic liquid (IL)-based electrolytes have garnered significant interest for enhancing lithium-ion battery (LIB) safety due to their non-flammability, thermal stability, high conductivity, and broad electrochemical stability. We propose novel pyrrolinium-based ionic liquids to enhance lithium-ion mobility and address safety concerns in LIBs. This study investigated LiTFSI in [Pyr13] [FSI] ionic liquid for Li-ion batteries. The cyclic stability and rate performance of single-layer full cells with commercial graphite anode and NMC532 cathode were examined for the electrolyte required per cell and compared to those using a carbonate electrolyte (LP30). Electrolytes containing LiTFSI/[Pyr13] [FSI] exhibited satisfactory rate performance and stable cycling for 100 cycles. The reversible capacity was maintained at over 22 mAh for a cycle period of 100 cycles with an electrolyte loading of 161.8 µL/cm2. These electrolytes exhibited the highest oxidation stability, surpassing 5.3 V compared to that of the Li+/Li reference electrode. Long cycle life of up to 1000 cycles was conducted, showing 80% capacity retention. Post-mortem analysis using scanning electron microscopy (SEM) and micro-Raman spectroscopy allowed observation of LiTFSI/ [Pyr13] [FSI] effects on cathode and anode active particle stability, and reduced formation of secondary reactions between the IL and battery electrodes. Full article
(This article belongs to the Special Issue Battery Manufacturing: Current Status, Challenges, and Opportunities)
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22 pages, 17449 KB  
Article
Investigation of Electrical and Physical Cell Parameters—A Comparative CT Study on Prismatic Battery Cells
by Daniel Evans, Julin Horstkötter, Daniel Martin Brieske, Claas Tebruegge and Julia Kowal
Batteries 2025, 11(11), 417; https://doi.org/10.3390/batteries11110417 - 13 Nov 2025
Viewed by 2126
Abstract
Computed tomography (CT) imaging has proven to be effective for detecting and visualizing a wide range of inhomogeneities and defects. Applying computer vision (CV)-based image processing enables detailed feature measurements on selected CT image slices, which could be of benefit as cells of [...] Read more.
Computed tomography (CT) imaging has proven to be effective for detecting and visualizing a wide range of inhomogeneities and defects. Applying computer vision (CV)-based image processing enables detailed feature measurements on selected CT image slices, which could be of benefit as cells of the same type often show variations in electrical properties. When combined with electrical testing, CT imaging could provide valuable insights into the battery cell, helping to identify potential sources of electrical deviations. However, it remains unclear to what extent CT-based measurements, especially for larger prismatic cells, e.g., those used in automotive applications, can explain electrical deviations aside from identifying significant or latent defects. Therefore, this study performs a correlative analysis and compares the electrical measurement results with CT-based measurements of the cell’s physical features, specifically the anode and cathode sizes. Electrical and CT measurements from ten lithium iron phosphate/graphite (LFP/C) cells of the same type are analyzed. The results indicate that while CT imaging has the potential to help identify the sources of electrical deviations, it also shows that cell-level CT measurements alone cannot fully explain electrical performance deviations. Measurement uncertainty, the potential overlapping impact of other cell features, and the actual influence of the measured physical properties on the cell’s electrical performance limit the correlation between CT-based measurements and electrical parameters. Full article
(This article belongs to the Special Issue Battery Manufacturing: Current Status, Challenges, and Opportunities)
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12 pages, 2405 KB  
Article
Impact of Inert Materials on Commercial Lithium–Ion Cell Energy Density
by William Yourey, Kayla Nong and Bhanu Babaiahgari
Batteries 2025, 11(10), 353; https://doi.org/10.3390/batteries11100353 - 27 Sep 2025
Viewed by 2333
Abstract
With the goal of increasing energy density in lithium–ion cells, new active materials continue to be developed and evaluated. Similarly, in commercial lithium–ion cells, inert materials present in manufactured cells should also be evaluated. The impact of the thickness of inert materials on [...] Read more.
With the goal of increasing energy density in lithium–ion cells, new active materials continue to be developed and evaluated. Similarly, in commercial lithium–ion cells, inert materials present in manufactured cells should also be evaluated. The impact of the thickness of inert materials on EV-sized lithium–ion cells was evaluated. The impact of the thicknesses of the positive current collector, negative current collector, separator, and aluminum laminate package on cell properties is presented. The impact of these materials varies greatly over different cell designs, with one of the largest impacts being from a decrease in separator material thickness, especially in cells with a high number of electrode pairs, specifically, cells with a larger thickness or cells with low-capacity loadings. For high-capacity positive electrode loading, a decrease in separator thickness from 16 to 8 microns results in an increase in stack volumetric energy density from 502 to 531 Wh/L or an increase of 5.7%. Full article
(This article belongs to the Special Issue Battery Manufacturing: Current Status, Challenges, and Opportunities)
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26 pages, 9543 KB  
Article
Design Analysis of 26650 and 18650 LFP Cells for High Power and Low Temperature Use Cases
by Florian Wätzold, Anton Schlösser, Max Leistikow and Julia Kowal
Batteries 2025, 11(1), 38; https://doi.org/10.3390/batteries11010038 - 20 Jan 2025
Cited by 4 | Viewed by 5883
Abstract
This study investigates the design and geometric properties of high-power and low-temperature 18650 and 26650 lithium iron phosphate (LFP) cells. The analysis focuses on the geometry and components’ thicknesses and deriving CAD models for both cell formats. Design variations were observed, even within [...] Read more.
This study investigates the design and geometric properties of high-power and low-temperature 18650 and 26650 lithium iron phosphate (LFP) cells. The analysis focuses on the geometry and components’ thicknesses and deriving CAD models for both cell formats. Design variations were observed, even within cells from the same manufacturer. For instance, one manufacturer’s 26650 cell was not a scaled-up version of their 18650 cell, and no equivalence was found between the designs of high-power and low-temperature cells from the same manufacturer. Thus, modifications are not purely chemistry based. The results also reveal deviations from the literature values for jelly roll component thicknesses, with anode current collectors averaging 61 µm and cathode current collectors averaging 60 µm. Coating thicknesses varied, with anode coatings averaging 32 µm and cathode coatings averaging 52 µm. These variations in current collector and coating thicknesses suggest that both high-power and low-temperature LFP cell designs differ from the typical literature values. Furthermore, a trade-off was observed between low-temperature operation with two-tab designs and high pulse capability with limited minimum operating temperatures. Additionally, smaller particle sizes in anode coatings were associated with lower impedance. Full article
(This article belongs to the Special Issue Battery Manufacturing: Current Status, Challenges, and Opportunities)
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14 pages, 4421 KB  
Article
The Effect of a Dual-Layer Coating for High-Capacity Silicon/Graphite Negative Electrodes on the Electrochemical Performance of Lithium-Ion Batteries
by Seonghyun Lim and Minjae Kim
Batteries 2024, 10(9), 320; https://doi.org/10.3390/batteries10090320 - 10 Sep 2024
Cited by 2 | Viewed by 5947
Abstract
Silicon-based electrodes offer a high theoretical capacity and a low cost, making them a promising option for next-generation lithium-ion batteries. However, their practical use is limited due to significant volume changes during charge/discharge cycles, which negatively impact electrochemical performance. This study proposes a [...] Read more.
Silicon-based electrodes offer a high theoretical capacity and a low cost, making them a promising option for next-generation lithium-ion batteries. However, their practical use is limited due to significant volume changes during charge/discharge cycles, which negatively impact electrochemical performance. This study proposes a practical method to increase silicon content in lithium-ion batteries with minimal changes to the manufacturing process by using dual-layer electrodes (DLEs). These DLEs are fabricated with two slurries containing silicon and graphite as active materials. Notably, the electrode with the silicon as the outermost layer on top of the graphite layer (Si-on-top) demonstrated a superior initial capacity of 935 mAh/g and retained 70% of its capacity (537 mAh/g) after 100 cycles at 0.5 C. In contrast, a single-layered electrode (SLE) with a silicon–graphite mixture retained only 50.3% of its capacity (370 mAh/g) under the same conditions. These findings suggest that DLEs, particularly with the silicon layer located on top, effectively increase silicon content in the negative electrode while remaining compatible with existing manufacturing processes. This approach offers a realistic strategy for enhancing the performance of lithium-ion batteries without significant process modifications. Full article
(This article belongs to the Special Issue Battery Manufacturing: Current Status, Challenges, and Opportunities)
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