Researchers at Fraunhofer Institute for Laser Technology ILT have outlined how laser-based manufacturing processes could help overcome key barriers to the industrial production of solid-state batteries. In a recent technical publication, the Aachen-based institute argues that advanced laser technologies may play an important role in bridging the gap between laboratory prototypes and large-scale manufacturing.
Solid-state batteries are widely seen as a potential successor to conventional lithium-ion technology. According to the institute, cells using solid electrolytes could enable higher energy densities through lithium metal anodes, improved safety compared with liquid electrolytes and greater flexibility in cell design. However, the transition from experimental laboratory cells to industrial production remains technically demanding.
“The path from the laboratory cell to industrial production is complex, but laser processes can overcome key challenges and enable the breakthrough,” researchers at Fraunhofer ILT wrote in the article.
Manufacturing challenges remain significant
One major challenge involves handling lithium metal anodes, which are highly reactive and sensitive to oxygen, moisture and mechanical stress. Conventional manufacturing processes such as cutting or rolling can therefore be difficult to apply reliably.
“Solid-state batteries will exist alongside conventional lithium-ion cells for the foreseeable future and will primarily serve particularly demanding applications in the automotive industry, such as the luxury vehicle market,” said Stoyan Stoyanov from the institute’s Cutting Group.
Solid electrolytes themselves also pose production challenges. Oxide-ceramic materials such as lithium lanthanum zirconate (LLZO) must be sintered at temperatures around 1,200°C, a process that can lead to lithium losses and the formation of unwanted secondary phases.
In addition, the interface between the electrolyte and lithium metal anode remains a critical bottleneck. High interfacial resistance can reduce performance and affect the stability of the battery cell.
“Mastering this interfacial chemistry is the foundation for stable and long-lasting cells,” explained Florian Ribbeck from the institute’s High-Temperature Functionalisation Group.
Laser processes as potential solutions
Fraunhofer ILT researchers are investigating how laser technology could address several of these issues. One research approach focuses on using laser radiation to densify oxide-ceramic electrolytes such as LLZO in a targeted manner. The process allows rapid heating combined with controlled cooling, which may reduce lithium losses and improve material stability.
The institute is also exploring laser-based microstructuring of electrolyte surfaces using ultrashort femtosecond pulses. According to researcher Tim Rörig, these structures can increase the contact area between the electrolyte and the anode, potentially improving current distribution and reducing interface resistance.
Another application involves cutting lithium-metal foils used as anodes. Compared with mechanical cutting methods, laser processing offers contact-free operation and allows more flexible geometries for battery design. However, both laser and mechanical processes must be carried out in controlled environments such as inert gas atmospheres or dry rooms to prevent chemical reactions.
Towards scalable production
The researchers emphasise that laser technologies are already used in lithium-ion battery production for tasks such as electrode cutting, drying and notching. Building on these established processes could help accelerate the industrialisation of solid-state battery manufacturing.
“That’s why laser processes are becoming increasingly important,” Stoyanov said. “Their contact-free, selective energy input enables high-precision machining that can be integrated into protected environments such as dry rooms or mini-environments.”
Fraunhofer ILT plans to expand its work across the entire solid-state battery value chain, including laser sintering of electrolytes, interface structuring, lithium-metal cutting and battery cell integration. The institute believes such manufacturing innovations could play a key role in making next-generation battery technology viable at industrial scale.