Researchers at RWTH Aachen University, working with industry partner Suragus, are developing a new technique to characterise battery electrode slurries during production, seeking to enhance quality control in cell manufacturing. The initiative, led by the university’s Chair of Production Engineering of E-Mobility Components (PEM), is funded by the German government and is scheduled to run until mid-2028.
Slurries—mixtures of active materials, binders, conductive carbon, and solvents—are a critical intermediate in the production of lithium-ion battery electrodes. These pastes are coated onto thin metal foils and dried before further processing. Variations in their composition or distribution can significantly affect battery performance, but current testing methods typically rely on laboratory analysis conducted after production steps are completed.
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The “MixItUp” project aims to enable real-time monitoring by measuring electrical conductivity, homogeneity, and particle distribution directly during mixing. “The quality of the slurry is crucial for the performance of battery cells, but current methods for its electrical characterisation involve time-consuming laboratory measurements that do not allow real-time process control,” said Professor Achim Kampker, Director of PEM. The team intends to develop an inline system that can be integrated into manufacturing equipment.
Data collected by the system will be compared with process parameters in a database to support continuous monitoring and early detection of production faults. “Eventually, we will enable continuous monitoring, early fault detection, and optimised process control,” said Professor Heiner Heimes, a PEM management member. The method will first be tested on a dedicated rig before being deployed on a pilot production line.
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The technology uses a contactless inductive sensor based on eddy currents, combined with FPGA-based real-time signal processing. Researchers aim to deliver an industry-ready measurement solution suitable for real manufacturing environments, with demonstrations planned in at least two industrial applications. While the primary focus is battery cell production, the partners said the approach could also apply to other functional pastes, including materials used in fuel cell manufacturing.