Scientists at the Fraunhofer Institute for Industrial Mathematics (ITWM) are employing advanced simulation and measurement techniques to enhance the performance and durability of battery cells used in electric vehicles.
The initiative aims to improve understanding of battery behavior during charging and discharging, as well as to optimize production processes and examine battery ageing. The results will be showcased at the Battery Show Europe 2025, taking place from June 3 to 5, where the institute plans to present an exhibit on inline layer thickness measurement of battery foil coatings.
A key focus of the research is the electrode, described as a core element influencing the entire battery cell’s performance. Researchers are leveraging ITWM’s in-house BEST simulation software to model the three-dimensional microstructure of electrodes in fine detail.
“We can use these insights to predict how the cell will behave during charging and discharging and then make targeted optimizations to improve the performance and efficiency of the battery,” said Jochen Zausch, team leader of Electrochemistry and Batteries at Fraunhofer ITWM.
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The project is also addressing battery production efficiency. As part of a state-funded initiative known as DiBaZ—short for “Digitalization of Battery Cell Production to Create a Battery Twin for the Entire Product Life Cycle”—researchers are building digital twins to simulate each major step in the manufacturing process. These include electrode calendering, electrolyte wetting, cell formation, and the foam encapsulation of cells for thermal insulation.
“Through the work in this project, we can offer our industrial partners methods and models that not only simulate processes from battery production, but also enable non-destructive quality control and include energy management with predictive control,” said Konrad Steiner, coordinator of the DiBaZ project.
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Fraunhofer ITWM said the simulations and predictive tools are intended to support industrial partners in the electric vehicle battery supply chain by streamlining development, reducing waste, and improving the consistency of final products.