Periodic Reporting for period 1 - C2C-CSA (Customized 21700 cylindrical cells for special applications)
Reporting period: 2024-07-01 to 2025-06-30
The European Union is increasingly focused on building a competitive, sustainable, and autonomous battery value chain in response to the growing demand for energy storage and the transition toward climate neutrality. At present, most lithium-ion battery electrodes are produced using solvent-based wet processing methods. These methods rely on hazardous chemicals such as N-Methyl-2-pyrrolidone, require significant energy input, and are largely dominated by non-European manufacturers. The result is a process that carries high environmental impact, elevated production costs, and complex infrastructure requirements.
This project aims to transform the current approach by implementing an innovative dry electrode processing technology. Unlike conventional methods, this process eliminates the use of solvents entirely, leading to a substantial reduction in energy consumption and a measurable decrease in the carbon footprint of each battery cell. Energy use is expected to decrease by approximately 27 percent, while carbon emissions per cell are projected to drop by up to 5 percent. In addition, the dry process significantly reduces capital and operational costs by removing the need for extensive drying equipment, air treatment systems, and solvent recovery infrastructure.
The main objective of the project is to establish the first industrial-scale production line in Europe for cylindrical 21700 lithium-ion battery cells using the dry electrode process. This facility will be the initial step toward a broader European manufacturing platform for battery cells. The production line is designed to supply flexible, high-quality cells that can be adapted to meet the specific needs of applications such as electric mobility, power tools, and high-performance vehicles. The project is focused on enabling a fully European value chain, from materials to finished cells, supporting the strategic goal of reducing reliance on external markets.
By advancing solvent-free battery manufacturing and building a local value chain, this project supports the European Union’s broader objectives of climate action, economic resilience, and industrial sovereignty. It establishes a foundation for scalable, sustainable, and customizable battery cell production within Europe and marks an important milestone in the continent’s path toward energy independence and technological leadership.
This project aims to transform the current approach by implementing an innovative dry electrode processing technology. Unlike conventional methods, this process eliminates the use of solvents entirely, leading to a substantial reduction in energy consumption and a measurable decrease in the carbon footprint of each battery cell. Energy use is expected to decrease by approximately 27 percent, while carbon emissions per cell are projected to drop by up to 5 percent. In addition, the dry process significantly reduces capital and operational costs by removing the need for extensive drying equipment, air treatment systems, and solvent recovery infrastructure.
The main objective of the project is to establish the first industrial-scale production line in Europe for cylindrical 21700 lithium-ion battery cells using the dry electrode process. This facility will be the initial step toward a broader European manufacturing platform for battery cells. The production line is designed to supply flexible, high-quality cells that can be adapted to meet the specific needs of applications such as electric mobility, power tools, and high-performance vehicles. The project is focused on enabling a fully European value chain, from materials to finished cells, supporting the strategic goal of reducing reliance on external markets.
By advancing solvent-free battery manufacturing and building a local value chain, this project supports the European Union’s broader objectives of climate action, economic resilience, and industrial sovereignty. It establishes a foundation for scalable, sustainable, and customizable battery cell production within Europe and marks an important milestone in the continent’s path toward energy independence and technological leadership.
Substantial progress was made in developing and validating dry electrode processing and high-performance cylindrical 21700 lithium-ion cells. High-quality anodes and cathodes were produced at pilot scale, specifically optimized for 21700 formats. The dry process was refined to ensure uniform layer formation, strong adhesion, and mechanical stability, meeting key performance criteria for energy density and rate capability.
Alongside electrode development, the project produced A-sample 21700 cell prototypes based on a proprietary design using a lightweight housing instead of conventional steel. This resulted in significantly improved gravimetric energy density. The cells demonstrated high capacity and excellent charge and discharge performance, outperforming current market benchmarks.
The project successfully validated both the cell design and chemistry, confirming compatibility with the dry electrode process. Based on these outcomes, a new generation of electrodes has been developed and is now being prepared for integration into B-sample prototypes. These will further enhance energy density and manufacturing efficiency, paving the way for industrial-scale production.
Alongside electrode development, the project produced A-sample 21700 cell prototypes based on a proprietary design using a lightweight housing instead of conventional steel. This resulted in significantly improved gravimetric energy density. The cells demonstrated high capacity and excellent charge and discharge performance, outperforming current market benchmarks.
The project successfully validated both the cell design and chemistry, confirming compatibility with the dry electrode process. Based on these outcomes, a new generation of electrodes has been developed and is now being prepared for integration into B-sample prototypes. These will further enhance energy density and manufacturing efficiency, paving the way for industrial-scale production.
The project has resulted in the development and validation of an advanced 21700 cylindrical cell that integrates a lightweight housing material and a customized high-performance cell chemistry. This combination enables gravimetric energy densities that exceed those of comparable commercial cells while maintaining excellent charge and discharge performance. These characteristics make the technology particularly suited for premium and high-demand applications.
The dry electrode process used to manufacture the electrodes has also proven to be compatible with this advanced cell format, providing a robust platform for future customization and scalability. The ability to tailor both cell design and electrode composition supports a high degree of flexibility for specialized use cases, while significantly reducing energy consumption and environmental impact during production.
To ensure further uptake and long-term success, several key needs have been identified:
Further development and industrial-scale demonstration of the dry electrode process.
Investment in production infrastructure and specialized equipment.
Commercialisation support including performance validation and customer qualification.
Protection of intellectual property and navigation of relevant patent environments.
These steps are essential to unlock the full potential of the technology and establish a competitive European manufacturing base for next-generation battery cells.
The dry electrode process used to manufacture the electrodes has also proven to be compatible with this advanced cell format, providing a robust platform for future customization and scalability. The ability to tailor both cell design and electrode composition supports a high degree of flexibility for specialized use cases, while significantly reducing energy consumption and environmental impact during production.
To ensure further uptake and long-term success, several key needs have been identified:
Further development and industrial-scale demonstration of the dry electrode process.
Investment in production infrastructure and specialized equipment.
Commercialisation support including performance validation and customer qualification.
Protection of intellectual property and navigation of relevant patent environments.
These steps are essential to unlock the full potential of the technology and establish a competitive European manufacturing base for next-generation battery cells.