Solid-state batteries (SSB) offer a promising opportunity for the EU to become an early player and enhance its position in the global battery market. Supported by a consortium comprised of key industry and academic players in the battery field, SOLVE aims to capitalize on the extensive R&D base and contribute to the scaling-up efforts required for SSB Gen4b mass production. To this end, SOLVE will address the most significant barriers hindering sector growth by demonstrating innovations across the main stages of the value chain, optimizing active and inactive materials, and associated processing techniques under industrially relevant conditions (TRL>=6). This will help achieve high-performing, cost-effective, and safe- and sustainable-by-design 20 Ah SSB prototypes and a proof-of-concept 0.25 kWh module based on: (i) thin, defect-free hybrid solid polymer based electrolytes (0.5 mS/cm @25-40ºC, >4.7 V); (ii) high loading solid state cathodes (>4.0 mAh/cm2) based on 4V-class cathode active materials (>200 mAh/g), and (iii) ultra-thin Li metal anodes (including cutting-edge lithophilic current collectors for the development of zero Li excess SSB) (3.000 mAh/g), all of them produced through easily scalable and sustainable R2R processes. This entire process will be reinforced by the implementation and adaptation of predeveloped digital tools and models to support and accelerate the SSB design, as well as the incorporation of imperative sustainability criteria to promote efficient resource utilization through eco-design principles and the development of innovative recycling processes. Finally, a robust dissemination, communication and exploitation strategy, including the development of tailor-made training activities and business models, will be established to propel SOLVE’s post-project commercialization and future market success, ultimately contributing to the decarbonization of the transport sector and the widespread adoption of electromobility.

Europe’s objective to have 30 million electric vehicles (EVs) by 2030 can only be achieved by large scale, in-house production of highly effective and performant batteries. Development of solid-state battery technologies could improve the energy density and safety of lithium metal solid state batteries. PULSELiON project aims to develop the manufacturing process of Gen 4b solid-state batteries (SSBs) based on lithium-metal anode, sulfide solid electrolytes, and Nickel-rich NMC cathode. Novel pulsed laser deposition technique developed by PULSEDEON will be adapted and modified into a single-step vacuum process for safe and efficient manufacturing of anode components composed of lithium metal, protective layers, and sulfide based solid electrolytes. The cathode layer will be made based on conventional wet processing techniques. Initially, the anode and cathode layers will be developed in small scale for making coin cells and monolayer cells for optimising the materials and process. SSB cells will be developed with optimised process routes and will be upscaled to a pilot line proof-of-concept (TRL 6) by manufacturing large scale solid-state batteries (10 Ah). Digitalisation will be incorporated in the process modelling task with the inputs obtained from process upscaling and cell testing tasks, which will enable efficient process optimisation.

Li-ion batteries are still the limiting factor for mass scale adoption of electrified vehicles and there is a need for new batteries that enable EVs with higher driving range, higher safety and faster charging at lower cost. LiS is a promising alternative to Li-ion free of critical raw material (CRM) and non-limited in capacity and energy by material of intercalation. LISA proposes the development of high energy and safe LiS battery cells with hybrid solid state non-flammable electrolytes validated at 20Ah cell level according to EUCAR industrial standards for automotive integration. LISA will solve specific LiS bottlenecks on metallic lithium protection, power rate, and volumetric energy density; together with cost the main selection criteria for EV batteries. The sustainability of the technology will be assessed from an environmental and economic perspective. The technology will be delivered ready for use within the corresponding state of charge estimator facilitating battery pack integration. Today, LiS is twice lighter than Li-ion and has reached only 10% of the sulphur theoretical energy density (2600Wh/kg) at cell prototype level (250-300Wh/kg), with potentially 800Wh/l (600Wh/kg) achievable by improving materials, components and manufacturing. LISA is strongly oriented to the development of lithium metal protection and solid state electrolyte; and will incorporate manufacturability concepts enabling integration in future manufacturing lines. Moreover, the outcome of the project in terms of new materials, components, cells, and manufacturability will be transferable to other lithium-anode based technologies such as Li-ion and solid state lithium technologies. As such, LISA will have a large impact on existing and next-generation EV batteries, delivering technology with higher energy density beyond the theoretical capacities of chemistries using CRM – i.e. natural graphite and cobalt - or silicon-based chemistries inherently limited by their manufacturability.

Although the global number of EVs has been increasing since 2010, EVs still have only 1.4% of global vehicle market share. This is mostly due to the fact that the development in the battery industry has been rather incremental, without revolutionary breakthrough since 1991’s launch of the first commercial Lithium-Ion batteries (LIB) by Sony. The advancement and maturity of the battery directly influence the industrialization of EVs. Thus, the biggest challenge the EV market is facing today is related to the limitations of batteries. These are mainly related to insufficient performance, in terms of size, energy density and safety (EV batteries are very flammable), and to expensive battery production, as available deposition methods generally fail to meet the requirements necessary to scale up and automate the production and require fixed casting on each battery specification type. Pulsedeon developed Coldab, a film coating process leveraging Ultra-Short Pulsed Laser Deposition (USPLD), that can optimize the production of LIB components on a large scale. Coldab’s unique PLD coating process allows cost-effective manufacturing of a new class of safer, smart tailored, high-performance EV batteries. Pulsedeon favors the competitiveness of European battery producers by offering a cutting-edge manufacturing process, and promotes a ‘clean environment’. In order to increase the EV’s affordability and improve their performance, Coldab brings EV’s battery manufacturing to a new level of scalability guaranteeing cost-effectiveness, at the same time preserving excellent performance by increasing the battery’s energy capacity and safety. During the phase 1 feasibility study, Pulsedeon will establish a sound go-to-market strategy and supply chain, and will draft further development plans. During the innovation project, Pulsedeon will optimize process automation, set up an industrial manufacturing line, and carry out in-vehicle testing with prospect customers.

Despite being an ideal solution to the global challenge of tackling the effects of transport emissions, Electric Vehicles (EVs) have not yet achieved significant mass market penetration. This is mostly due to the fact that the development in the EV battery industry has been rather incremental, without revolutionary breakthrough since 1991. LiBs represent the gold standard in the industry; however, they suffer from many issues which are detrimental to the widespread adoption of EVs. These are mainly related to insufficient performance, in terms of size, energy density and safety, expensive and rigid production while existing deposition methods has low production rate thus affecting the overall supply of EVs in comparison to high-growth demand (CAGR of 20%). Pulsedeon developed Coldab, a coating technology leveraging Ultra-Short Pulsed Laser Deposition (USPLD), that can optimize production of LiB & its components on a large scale. Coldab’s unique USPLD process allows cost-effective manufacturing of a new class of safer, smart tailored, high-performance EV batteries. Pulsedeon favours the competitiveness of European battery manufacturers by offering a cutting-edge manufacturing process and promotes a clean environment. To increase the EV’s affordability & improve their performance, Coldab brings battery manufacturing to a new level of scalability, at the same time preserving performance by increasing the battery’s energy density and safety. Overall objective of Pulsedeon is to introduce a paradigm shifting within EV battery manufacturing process to facilitate the widespread adoption of EVs. During the innovation project, Pulsedeon intends to upgrade & validate Coldab system to automate the production of LiBs & its components, conduct extensive validation tests of the system and produced LiBs, setup a scalable supply chain & finally conduct pilot tests with 8 battery OEMs confirming technology’s performance and advantages in a commercial environment.