Optimization of Production Processes for Solid-State Batteries: A Methodology for Scaling from Laboratory to Mass Production

Solid-state batteries represent a critical advancement in energy storage technology, offering higher energy density, enhanced safety, and faster charging times compared to traditional batteries with liquid electrolytes. The transition from laboratory-scale prototypes to mass production presents significant challenges, including the scaling of manufacturing processes and the reproducibility of material properties. These challenges arise from complex interactions among materials selection, electrode fabrication, cell assembly processes, and the incorporation of solid electrolytes. The low technology readiness level additionally complicates scalability for commercial applications. A novel methodology for scaling up solid-state battery production has been introduced. This approach involves preemptive adjustments to production processes to seamlessly meet final product specifications. A systematic framework aids in deriving production needs from early-stage predictions, identifying suitable technological pathways, and strengthening manufacturing research to develop scalable production methods effectively. In a specific case study, this methodology was applied to the compaction of oxide-based electrolytes. This step is crucial for overcoming the current barriers to commercial scalability of solid-state batteries, thereby accelerating the transition towards safer and higher-capacity energy storage solutions.