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DRY proceSsing with advancEd materials and automated process coNtrol for high performance Solid-state battEries manufacturing

Objective

DRY-SENSE addresses a critical bottleneck in Europe’s transition from conventional lithium-ion batteries to next-generation solid-state batteries (SSBs), which are essential for high-performance, safety-critical applications such as aviation, maritime transport, rail and premium mobility. While SSBs promise higher energy density, improved safety and longer lifetime, their industrial deployment is constrained by wet, solvent-based manufacturing processes that are energy-intensive, costly and poorly compatible with solid-state materials. DRY-SENSE aims to demonstrate a fully dry, solvent-free and energy-efficient manufacturing route for solid-state batteries at TRL 6 in a pilot coating-line industrial environment, enabling the upgrading of existing Generation-3 lithium-ion production lines through targeted retrofitting. The project combines advanced battery materials—including silicon-rich anodes, cobalt-reduced or cobalt-free cathodes, and next-generation polymer electrolytes—with fully dry manufacturing processes, notably multi-material extrusion and advanced roll-to-roll systems for electrode coating and electrolyte production. These innovations are supported by advanced digitalisation, including inline sensing, artificial intelligence and digital twins, to ensure product quality, minimise defects and optimise process efficiency under industrially relevant conditions. Pilot-scale validation will deliver 10 Ah solid-state cells, providing robust evidence of technical, economic and environmental feasibility. DRY-SENSE is expected to reduce manufacturing energy consumption by up to 40–50% and production costs compared to current lithium-ion processes, while reducing dependence on critical raw materials. Finally, the project delivers a replicable industrial blueprint for an integrated, low-impact manufacturing process, achieving higher resource efficiency, fewer defects and a lower CO2 intensity, supporting future gigafactory deployment across Europe.

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Keywords

Project’s keywords as indicated by the project coordinator. Not to be confused with the EuroSciVoc taxonomy (Fields of science)

Programme(s)

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Topic(s)

Calls for proposals are divided into topics. A topic defines a specific subject or area for which applicants can submit proposals. The description of a topic comprises its specific scope and the expected impact of the funded project.

Funding Scheme

Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.

HORIZON-RIA - HORIZON Research and Innovation Actions

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Call for proposal

Procedure for inviting applicants to submit project proposals, with the aim of receiving EU funding.

(opens in new window) HORIZON-CL5-2026-01

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Coordinator

ACONDICIONAMIENTO TARRASENSE ASSOCIACION
Net EU contribution

Net EU financial contribution. The sum of money that the participant receives, deducted by the EU contribution to its linked third party. It considers the distribution of the EU financial contribution between direct beneficiaries of the project and other types of participants, like third-party participants.

€ 997 353,75
Address
CARRER DE LA INNOVACIO 2
08225 Terrassa
Spain

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Region
Este Cataluña Barcelona
Activity type
Research Organisations
Links
Total cost

The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.

€ 997 353,75

Participants (19)

Partners (1)