Design and implementation of a flexible prototype assembly system for lithium-metal-based all-solid-state batteries

All-solid-state batteries (ASSBs) with lithium metal anodes represent a potential future battery technology due to their increased energy density and operational safety. The modified materials and cell design compared to the currently predominating lithium-ion batteries (LIBs) entail significant changes in manufacturing, rendering existing industrial battery production lines incompatible with lithium-metal-based ASSB fabrication. This study introduces a research-grade, semi-automated prototype production system for assembling lithium-metal-based ASSBs with various solid electrolyte types, detailing the adaption from LIB manufacturing processes to those suitable for ASSBs. Key focus areas include the transition in lamination, cutting, and stacking processes, with special emphasis on the integration of equipment within controlled atmospheric environments. The installation of a calender within a glovebox system for thinning and laminating ASSB components is discussed. Additionally, the implementation of a laser system for precise shaping and surface treatment of electrodes and electrolyte materials is presented. The development of a robotic handling system for cell stacking is explored, facilitating the use of different gripping principles for handling delicate lithium and sheet-type solid electrolyte layers. This research supports stakeholders from research and industry in identifying essential equipment modifications for lithium-metal-based ASSB production, providing a foundation for next-generation battery assembly systems.