Nothing is impossible? There is no such thing as “Can’t be done”? What sounds like hackneyed advertising slogans to some people is reality for the Fraunhofer Research Institution for Battery Cell Production FFB in Münster, Germany. In an exclusive interview with “Battery-News,” FFB Managing Director Dr. Simon Lux, Professor of Applied Electrochemical Energy Storage Technology and Industrial Chemistry at the University of Münster, explains how and with what Germany and Europe can assert themselves in competition, especially with Asia, and why it is better for the future to put regulations on the back burner and just test new technologies first.
Battery-News: Despite their technical limitations, lithium-ion batteries are the standard in many industrial sectors. What new material developments is Fraunhofer FFB currently pursuing that could improve the performance and sustainability of lithium-ion batteries?
Professor Dr. Simon Lux: We are continuously working on optimizing the battery cells manufactured at Fraunhofer FFB. We use nickel-rich cathodes and silicon-containing anodes to improve our cells’ performance. At the same time, we are researching sustainable production methods that work either without toxic solvents or without fluorine-containing binders. Another research focus is on sodium-ion batteries and lithium iron phosphate batteries, which are known to be a more sustainable alternative because they rely on less critical raw materials and have a reduced carbon footprint.
Battery-News: Despite high investments, many innovative battery technologies fail to reach market maturity. What is the Fraunhofer FFB doing to ensure that research results can be transferred to large-scale production more quickly instead of ending up as prototypes?
Lux: This gets right to the heart of the Fraunhofer FFB. Our mission is to ensure that innovative battery technologies not only exist on paper, but are also transferred to industrial application. With our FFB PreFab as an open research factory, we provide an infrastructure and expertise for this purpose. In addition, the later FFB Fab will create 20,000 square meters of additional production and research space, where industry-oriented manufacturing research and development in the gigawatt range will be possible. At the same time, we are making targeted use of our expertise in our development projects with industrial customers. Our partners know their own processes inside out, but they do not always have in-depth, helpful insights into the battery industry. We can easily close this knowledge gap.
“Our goal must be to find a balance between cost and energy efficiency and explicitly European strengths such as quality, sustainability, and innovation.”
Battery-News: Manufacturing costs for battery cells in Europe are significantly higher than those in Asia. How would Fraunhofer FFB like to help compensate for this competitive disadvantage? Is it even realistic for Europe to become competitive?
Lux: Manufacturing costs for battery cells in Europe are undoubtedly higher than in Asia. This is mainly due to the economies of scale there and government support for producers, for example in China. The market prices for battery cells there are sometimes lower than the calculated material and production costs. Nevertheless, Europe has a realistic chance of becoming competitive. Our goal must be to find a balance between cost and energy efficiency and explicitly European strengths such as quality, sustainability, and innovation. Fraunhofer FFB makes a significant contribution to this. One central aspect is the qualification of specialists in order to build up the necessary know-how for competitive cell production in Europe. Another decisive factor is our practical research, which provides us with in-depth insight into the relationships between product and process, optimized production processes and lower reject rates.
Battery-News: Sustainability is now considered a key issue in the battery industry. How is Fraunhofer FFB tackling the challenge of designing batteries in such a way that they can be recycled cost-effectively later on? Do you see progress in the circular economy?
Lux: Sustainable and resource-conserving battery cells are crucial for the future of battery technology. We are focusing on sustainable production, which includes the direct recycling of production waste. In other projects we are researching how valuable raw materials for battery production can be recovered from ceramic fields and agricultural waste in the medium term and re-used in new batteries. We are also working on recovering phosphate from waste water and sewage sludge to make it usable again as electrode material for LFP batteries. Our aim is to use innovative recycling processes to make the battery value chain more sustainable and fit for the future.
“The development of new battery cells is extremely cost-intensive from prototype construction onwards.”
Battery-News: European industry urgently needs marketable technologies, but the gap between research and production often remains wide. How do you ensure that FFB’s developments are actually taken up and implemented by industry?
Lux: It is precisely this “valley of death” between research and production that we are closing with the establishment of the Fraunhofer FFB. The development of new battery cells is extremely cost-intensive from prototype construction onwards, as it requires well-established processes for validation. With the FFB, we are creating a bridge with which innovations can be efficiently transferred to industrial application, and we are already experiencing great interest in this offer from leading automotive OEMs and SMEs. The response is tangible. Our expertise in the areas of innovative process technology, technology management, sample production, and quality management in battery cell production meets the industry’s current needs. Particularly in quality management, our focus is on transferring established concepts from the automotive industry to the requirements of battery cell production. So far, there are only a few battery cell factories in operation in Germany and Europe. We know that especially the start-up phase of a gigafactory is associated with considerable organizational and technical challenges. That is why we have systematically analyzed the ramp-up phase and recently published our findings. We offer targeted support to make this process significantly more efficient and therefore more cost-effective.
Battery-News: Where will European battery production likely be in ten years’ time?
Lux: Germany’s and Europe’s battery industry is currently going through a phase of consolidation in which many companies are rethinking their ambitions or even scaling back specific projects. In view of the sometimes extremely favorable financing options and the enormous growth of the battery market in recent years, this is not entirely unexpected but is also only an interim low. Batteries remain the key driver of the energy and mobility transition and will continue to grow strongly, as it did in 2024 from a global perspective.
“The competition is not only coming from China but also from other Asian countries such as India and Taiwan.”
Battery-News: In which area do you see Germany’s and Europe’s best opportunities?
Lux: There is enormous potential in production optimization. However, this is heavily dependent on key factors: How easy, how cost-effective and how sustainable can a battery be produced? In order to drive forward relevant innovations, targeted funding is needed to support long-term developments – as opposed to temporary funding and regulations that slow down progress. The 25 million euros recently announced by the German Federal Ministry of Research are an important first step towards bridging some of the shortfall in KTF funding. Nevertheless, the next federal government will have to get to work. Our goal must be to remain at the forefront as an industry location – and for this we need innovation, speed, and determination. The competition is not only coming from China but also from other Asian countries such as India and Taiwan. Europe has the chance to take a leading role in this race. But before we again start to regulate, we should first test new technologies. This is the only way we can shape real progress and assert ourselves in global competition.
