Key Findings
The SOLiD project has developed a scalable manufacturing framework for next-generation solid-state lithium-metal batteries (SSBs). Key breakthroughs include the implementation of roll-to-roll (R2R) dry extrusion coating for cathodes and the development of a polyester-based polymer electrolyte, PESDA, which retains 95% of capacity after 120 cycles in prototype cells and exhibits tensile yields up to 250% before failure.
Technical Details
To eliminate toxic solvents and energy-intensive drying, SOLiD utilizes R2R dry extrusion coating to blend active cathode material, polymer binder electrolyte, and conductive additives. The use of ALD-protected NMC811 allows this process to occur under ambient conditions, removing the requirement for dry rooms. On the anode, the project scaled pulsed laser deposition (PLD) to create lithium layers under 10 micrometres in thickness, topped with a protective lithium-alloy layer to prevent dendrite formation.
The production line incorporates a digital twin—an AI-driven feedback and feedforward system. This system integrates data from particle detection, optical monitoring, and electrochemical impedance spectroscopy to provide near real-time quality assurance and optimize yields.
Background and Context
Launched in September 2022, SOLiD consists of 13 partners across eight countries. The project addresses the limitations of traditional lithium-ion batteries, specifically the volatility of liquid electrolytes and the reliance on critical raw materials like cobalt. By replacing graphite anodes with lithium metal and using solid polymers, these SSBs can store up to 70% more energy in the same volume while reducing fire risks.
Significance and Outlook
The transition to pilot-scale production—including kilo-scale ALD processing and validated roll-to-roll PLD-deposited lithium in coin cells—marks a shift toward industrial viability. These advancements provide a roadmap for European battery sovereignty by creating a template for future gigafactories that prioritize recyclability by design and reduced environmental impact through solvent-free manufacturing.
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