RWTH Aachen is developing scalable manufacturing for multi-layer electrodes
In the ProMeBa research project, RWTH Aachen is developing scalable methods for multi-layer battery electrodes. The goal is to transition from laboratory scale to pilot scale.
Multi-layer battery electrode in the ProMeBa research project.
Image: PEM RWTH Aachen
The “Production Engineering of E-Mobility Components” (PEM) research group at RWTH Aachen launched the “ProMeBa” research project in June 2026 together with several partners. The project runs until May 2029 and is carried out under the BMFTR announcement “B@TS.”
Multilayer electrodes offer advantages, but their manufacturing is significantly more complex than that of conventional single-layer structures. ProMeBa aims to demonstrate how such electrodes can be produced stably and reproducibly on an industrial scale. By using differently structured layers, it is intended to improve ion transport, enhance the mechanical stability of the electrode, and increase the battery’s performance and lifespan.
At the beginning of the project, suitable materials and layer architectures for anodes and cathodes are investigated. Key factors include the number of layers, the thickness of each layer, and possible composition gradients. The resulting electrode concepts are then implemented and characterized on a laboratory scale using customized slurry formulations as well as coating and drying parameters.
Multilayer Electrodes Moving Toward Pilot Scale
PEM is responsible for developing the formulations and processes for multilayer anodes, as well as their characterization on a laboratory scale. The insights gained will then be applied at pilot scale.
To achieve this, a modular coating module is being developed that can be integrated into existing pilot plants. Two processes under industrially relevant roll-to-roll conditions are being studied: multilayer coating using a two-layer slit die, and multilayer curtain coating. The key is to identify the solution that combines high coating quality, stable process conditions, and good scalability.
Meanwhile, an inline measurement technique is being developed to continuously determine the viscosity of electrode slurries. This aims to detect process deviations early and ensure reproducible electrode quality.
The produced electrodes and test cells are also examined electrochemically. Insights into the performance, stability, and lifespan of the developed multi-layer structures are intended to be derived from these tests.
The project coordinator is Netzsch-Gerätebau GmbH. Other partners include PEM, as well as the ISEA research group at RWTH Aachen, Fraunhofer IKTS, the iPAT institute at Braunschweig University of Technology, and 8inks Deutschland.
The industrial 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” technology that allows existing production infrastructure to be expanded specifically, rather than building entirely new manufacturing lines for multi-layer electrodes.
ProMeBa fits into a series of research projects that closely link material development with industrial scaling. For example, the MoSiLIB project led by AIT is working on a composite anode made of silicon and zinc sulfide, while also investigating the semi-industrial scaling of its synthesis process as well as water-based electrode manufacturing. While MoSiLIB focuses primarily on developing new anode materials, ProMeBa emphasizes how more complex electrode architectures can be reproducibly integrated into existing production processes.
