As the global push toward climate neutrality accelerates, the demand for cleaner, more efficient energy storage solutions has never been more urgent. Electrified vehicles and stationary storage systems are at the heart of this transition—but the sustainability of lithium-ion battery production remains a critical challenge.
Addressing this, researchers at Fraunhofer IWS, led by Benjamin Schumm, Holger Althues, and Stefan Kaskel, have pioneered DRYtraec, a breakthrough dry coating method that could transform how batteries are made.
Traditional battery manufacturing relies on a wet chemical process involving slurry—an energy-intensive method that uses toxic solvents and requires large-scale drying equipment. This not only inflates the environmental footprint but also raises production costs and complexity.
Holger Althues, Stefan Kaskel and Benjamin Schumm from Fraunhofer IWS
DRYtraec upends this norm. It enables the creation of battery electrodes without a single drop of solvent, using a dry mixture of active material, conductive carbon black, and binders. These components are mechanically fused into a stable, high-performance electrode layer using a specialized calendering process that eliminates the need for drying altogether.
The advantages are striking. DRYtraec delivers all the performance benefits of conventional electrodes while removing one of the most resource- and energy-intensive steps in the production line. It also supports double-sided coating in a single step, allowing for greater throughput and more compact manufacturing footprints.
Born out of over a decade of research and development—the first prototype dates back to 2013—DRYtraec has matured into a scalable, roll-to-roll process suitable for industrial deployment. With a modular R&D platform in place, Fraunhofer IWS now offers industry partners a comprehensive pipeline from concept to commercialisation. Licensing the technology to a leading European automotive player marks a significant milestone in taking this innovation from lab to line.
Importantly, DRYtraec isn’t confined to lithium-ion technology. The method has proven compatible with emerging battery chemistries, including sodium-ion, lithium-sulphur, and solid-state batteries—areas where conventional wet processing compromises material performance. Its 'drop-in' adaptability makes DRYtraec not just a future-ready tool, but a critical enabler for next-generation battery platforms.
For Germany and Europe, this innovation arrives at a pivotal moment. As regions race to localise clean technology value chains and retain industrial competitiveness, DRYtraec strengthens Fraunhofer IWS’s role as a cornerstone in sustainable mobility and advanced manufacturing. By redefining battery production with a solvent-free, energy-efficient process, DRYtraec is more than just a technical milestone—it is a foundation for greener power, smarter factories, and a more resilient energy future.
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