Dürr and Grob, two leading mechanical engineering firms, have presented their joint concept factory for lithium-ion battery cell production at the Battery Show Europe. The new factory design integrates innovations aimed at boosting battery cell quality and performance while cutting energy consumption and footprint.
Among the key technologies showcased is a dry coating process for electrodes that eliminates the need for conventional drying ovens, traditionally a major energy consumer. Instead of slurry, the “Activated Dry Electrode” method uses a dry-mixed active material pressed into free-standing films and laminated onto collector foils. This approach reduces space requirements by half and enhances material efficiency, according to the companies.
Jochen Weyrauch, CEO of Dürr AG, said, “Our concept factory and dry coating in particular represent the next generation of battery cell production. Thanks to powerful and innovative technologies, production requires 50 percent less space and energy. This means significantly higher space efficiency and lower operating costs for our customers.”
The partners also highlight their new Z-folding technology for cell assembly, featuring an integrated notching process that minimizes system size while ensuring high system stability and availability of up to 95 percent. Furthermore, electrolyte filling has been improved by increasing operating pressures up to 30 bar, which shortens process times and allows more precise dosing.
Grob Group CEO German Wankmiller added, “With our expanded portfolio of high-availability machines and systems, together we cover almost the entire value chain for battery cell production with our own technologies.”
Dürr and Grob have collaborated since 2022 to establish a strong position in battery production systems across Europe and North America. The partnership continues following the insolvency of Manz, a former alliance partner.
Visitors to Battery Show Europe in Stuttgart, running until June 5, can view the concept factory as a detailed 3D model, along with demonstrations of other technologies, including full digitalisation of the production process, from digital twins in planning through to traceability and quality control during manufacturing.