Results

List of publications

Sustainable and high-performance anode development

The partners develop a diversity of sustainable anode technologies for next generation Li-ion batteries, including several advanced processing and material engineering routes. In this start of the project one of the aspects the SMART-CBAT project focuses on is stabilizing silicon-dominant anodes for Li-ion batteries by applying nanoscale coatings via Atomic Layer Deposition (ALD). These coatings, applied by Powall to E-magy’s porous silicon, mimic the solid-electrolyte interphase (SEI) to mitigate challenges such as large volume expansion and electrolyte reactivity. Initial tests utilized sustainable water-based and water-free preparation processes. Despite the water-solubility of specific coatings the treated anodes demonstrated improved stability in half-cell configurations compared to pristine silicon. Future testing will transition to full-cell configurations using commercial NMC-based cathodes to validate long-term cycle life. This work provides the foundation for subsequent experimental validation within the consortium.

Sustainable Cathode Development

SMART-CBAT is transforming cathode production by replacing energy-intensive, toxic processes with dry coating, low-solvent, and water-based alternatives. These methods eliminate carcinogenic NMP solvents and significantly reduce environmental impact. Key results and progress till now include:

• PFAS-free Binders: Research has moved away from Teflon-based systems, identifying promising alternatives like polyacrylates, aliphatic polymers, and biopolymers to improve recyclability.
• Advanced Coatings: A database of over 100 nanocoating chemistries was established. Atomic Layer Deposition (ALD) benchmarks identified specific coating chemistries as critical for protecting nickel-rich cathodes against degradation and microcracking.
• Process Optimization: Initial studies defined essential parameters for binder particle size and thermal stability, ensuring compatibility with high-performance, sustainable materials.

These innovations bridge the gap between lab-scale sustainability and industrial requirements, paving the way for the development of fluor-free, high-energy batteries with a drastically reduced carbon footprint.

Sustainable Electrolyte Development

The SMART- CBAT consortium develops liquid, polymer and solid electrolytes that are compatible with the developed anode and cathode technology to maximize their performance.

Key results achieved till now include:

• Research and specific chemistry roadmaps were developed for locally concentrated and weakly concentrated electrolytes aiming to enhance interphase stability.
• For inorganic solid-state electrolytes, two primary inorganic sulfide-argyrodite candidates were selected combining both good initial electrochemical performance with realistic industrial-scale processing, which will be further developed and evaluated.
• The shift towards solvent-free dry-coating was validated, identifying promising fluorine-free binders (e.g., polyacrylates and bio-derived polymers) that maintain mechanical integrity without the regulatory risks of PTFE.

These milestones set the starting point to improve these materials and processes, ultimately to bridge the gap between lab-scale chemistry and large-scale manufacturing, ensuring a sustainable, high-performance battery ecosystem.

Integration of Sustainable Battery Components in Demonstrative Scale Battery Cells, and Development of Characterization Techniques

Work Package 4 of the SMART-CBAT project focuses on integrating innovative components into full-cell prototypes across three tracks: advanced Li-ion, semi-solid-state, and solid-state batteries.

First Key Results and Achievements include:

• Standardization: Partners successfully aligned on universal exchange protocols, material handling safety, and standardized electrochemical testing (defining N/P ratios and pouch cell designs) to ensure data reproducibility.
• Material Synergy: Initial integration of 3D-carbon, silicon (PECVD/powder), and Li-metal anodes with sustainable cathodes and varied electrolytes (liquid to solid) is underway.
• Process Optimization: Development of tailored cell formation strategies has begun, targeting reduced energy consumption and time during the critical SEI-formation phase.
• Interface Engineering: Implementation of s-ALD protection layers has started to address interface compatibility and cycle life.
• Advanced Diagnostics: Workflows for operando characterization were established, including the conceptual design of an in-situ cycler to analyze failure mechanisms in real-time.

These milestones provide the essential framework for demonstrating high-performance, scalable battery cells.

Scalability Studies of Sustainable Battery Components and Cells

Work Package 5 focuses on bridging the gap between laboratory research and industrial battery production. Partners including E-magy, CarbonX, TNO, and LeydenJar are validating and scaling equipment to meet the performance and cost targets required for advanced battery chemistry.

Key Achievements and Results till now include:

• Silicon Anode Production: Successfully installed specialized equipment to handle silicon layers, which are three times thinner and more sensitive than standard graphite.
• Roll-to-Roll (R2R) Coating: Finalized a 3D design and flexible test-setup for lithium deposition, achieving precise web handling and tension control for industrial throughput.
• Sustainable Manufacturing: Produced coated cathode materials that remain stable during eco-friendly, water-based processing, preventing material degradation.
• Testing Infrastructure: Developed a dedicated 5Ah cell holder that maintains constant mechanical pressure—critical for silicon battery lifespan—and established requirements for inline CT-scanning.
• Digitalization: Created a structured data overview of the entire production line to enable future AI-driven process optimization.

Sustainability & Market Analysis

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Other

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