IDEEL Project Achieves Laser Drying Breakthrough for Efficient Battery Cell Production
Key Insights
The IDEEL project in Germany developed a laser-assisted roll-to-roll drying process, reducing lithium-ion battery manufacturing costs by 20-30%.
The hybrid process combines laser and convection drying, cutting drying times by over 60% while maintaining quality.
The innovation allows retrofitting existing plants with laser modules, halving oven length and energy use.
Supported by the German government, the project involved leading research institutions and industry partners like Fraunhofer FFB and Laserline.
The Implementation of Laser Drying Processes for Economical & Ecological Lithium Ion Battery Production (IDEEL) project has achieved a significant breakthrough in battery cell manufacturing efficiency. Researchers in Germany developed a laser-assisted roll-to-roll (R2R) drying process that could substantially reduce the cost and energy consumption of lithium-ion battery production. The hybrid process, which combines conventional convection drying with high-power diode laser drying, achieves a web speed of 30 meters per minute and slashes drying times by more than 60% without compromising quality.
The innovation is particularly notable for its practicality. By integrating laser modules at the start of the drying process, the required oven length is halved, reducing energy-intensive drying room needs and cutting operational costs by 20-30%. This adaptability allows the process to be retrofitted into existing manufacturing plants, making it a scalable solution for the industry.
The IDEEL project, completed on December 31, 2024, after a three-year term, was supported by the German Federal Ministry of Education and Research under the Battery 2020 funding program. Led by Laserline, the project brought together key players such as Fraunhofer FFB, RWTH Aachen University, Coatema Coating Machinery, Optris, and the University of Münster’s MEET Battery Research Center. The collaboration focused on optimizing laser drying processes and developing new materials for anode and cathode coatings, including aqueous formulations based on graphite, lithium iron phosphate, and silicon-graphite.
A high-efficiency diode laser system, with an electrical efficiency exceeding 50%, served as the heat source. The system featured a rectangular laser spot over 0.5 meters wide and integrated thermography for real-time process monitoring. Coatema contributed a modular laser drying unit with specialized air nozzles, enabling the process to be scaled to industry-standard speeds. The findings from IDEEL will now be integrated into Fraunhofer FFB’s work, positioning it as a development hub for modern battery cell production in Europe.