Battery Manufacturing

Batteries represent a key technology for electromobility, energy storage, and industrial transformation. At the same time, practical requirements are increasing significantly. In 2024, global demand for batteries reached 1 TWh for the first time - with electric vehicles already accounting for over 950 GWh of this total. In parallel, cost pressures, quality standards, and the need for rapid production ramp-ups are on the rise. Added to this are new regulatory mandates regarding transparency and traceability. As of February 2027 the EU will require digital product passports for vehicle batteries. Furthermore, because batteries must be considered across their entire lifecycle, the end-of-use phase is also coming into sharper focus. By 2040 Europe is expected to face a volume of approximately 1.5 million tons of end-of-life lithium-ion batteries and battery components.

This is precisely where we - the participating Fraunhofer Institutes within the Fraunhofer Group of Production - step in. We provide support across the entire battery value chain: from material and cell concepts, through prototype cells, cell manufacturing, and production processes, all the way to factory planning, industrialization, quality management and digital traceability. To achieve this, we combine process expertise with manufacturing engineering, automation, data analytics and digital IT architectures. This approach enables faster evaluation of new battery solutions, earlier identification of investment risks, and the more rapid transfer of developments into scalable production chains.

To ensure that battery technologies do not stop at the cell level, we also address the systems and circular economy aspects. We develop battery packs and battery systems; provide support in lightweight design, thermal management, and application integration; and lay the groundwork for "second life" applications, remanufacturing, and recycling. Additionally, we consider logistics, safety requirements, and regional value chains to ensure that batteries are deployed in a manner that is economically viable, fully traceable, and sustainable. We offer a comprehensive suite of services - spanning the entire journey from initial concept and design through production and quality assurance, to circular utilization.