RWTH Aachen develops scalable manufacturing for multi-layer electrodes
Under the ProMeBa research project, RWTH Aachen is developing scalable processes for multilayer battery electrodes. The goal is to transfer the technology from the lab to pilot scale.
Multilayer battery electrode in the ProMeBa research project.
Image: PEM RWTH Aachen
The Chair of Production Engineering of E-Mobility Components (PEM) at RWTH Aachen, together with several partners, first launched the ProMeBa research project in June 2026. The project will run until May 2029 and is being conducted as part of a German Federal Ministry for Economic Affairs and Climate Action (BMWK) scheme.
Multilayer electrodes offer significant advantages but are far more challenging to manufacture than conventional single-layer structures. ProMeBa therefore aims to demonstrate how such electrodes can be produced stably and reproducibly on an industrial scale. Differently structured layers are intended to improve ion transport, enhance the mechanical stability of the electrode, and increase the performance and lifespan of the battery.
At the beginning of the project, suitable materials and layer architectures for anodes and cathodes will be investigated. The focus will be on aspects such as the number of layers, individual layer thickness, and possible composition gradients. The derived electrode concepts will then be implemented and characterised in the laboratory using adapted slurry formulations as well as coating and drying parameters.
Multi-layer electrodes on the path to pilot scale
PEM is primarily responsible for the formulation and process development of multi-layer anodes, as well as their characterisation at laboratory scale. The insights gained will subsequently be transferred to pilot scale.
For this purpose, a modular coating module will be developed that can be integrated into existing pilot plants. Two processes will be examined under industrially relevant roll-to-roll conditions: multi-layer coating using a two-layer slot die and multi-layer curtain coating. The decisive factor is which solution combines high coating quality, stable process conditions, and good scalability.
In parallel, an inline measurement technique for the continuous determination of the viscosity of electrode slurries will be further developed. This is intended to detect deviations in the process at an early stage and ensure reproducible electrode quality.
The manufactured electrodes and test cells will also be electrochemically examined. This should provide insights into the performance, stability, and lifespan of the developed multi-layer structures.
The project coordinator is Netzsch-Gerätebau GmbH. In addition to PEM, other partners include the ISEA Chair at RWTH Aachen, Fraunhofer IKTS, the iPAT Institute at Technische Universität Braunschweig, and 8inks Deutschland.
The industrial added value lies primarily in the fact that ProMeBa not only develops new electrode structures but also considers their manufacturing from the outset. The project partners aim to create a “drop-in capable” technology that allows existing production infrastructures to be selectively expanded, rather than building entirely new production lines for multi-layer electrodes.
ProMeBa thus joins a series of research projects that more closely link material development and industrial scaling. For example, the AIT-led MoSiLIB project is working on a composite anode made of silicon and tin sulfide while simultaneously investigating the semi-industrial scaling of synthesis and water-based electrode manufacturing. While MoSiLIB primarily develops new anode materials, ProMeBa focuses more on the question of how complex electrode architectures can be reproducibly integrated into existing production processes.
