Engineering companies Dürr and GROB will present a concept factory for lithium-ion battery cell production at The Battery Show North America 2025 in Detroit from October 6th to 9th, at Huntington Place in Detroit.(Booth 3822). The design incorporates new approaches aimed at reducing space and energy requirements while maintaining high cell quality.
The concept factory developed by Dürr and GROB compares a state-of-the-art process with a
next-generation process that requires 50% less space and 70% less energy.
Key technologies include dry electrode coating, which eliminates the need for a drying process, and a new generation of Z-folder technology for cell assembly that integrates notching.
Dürr and GROB have been cooperating in battery production technology since 2022, with the goal of positioning themselves as system suppliers for cell production equipment in Europe and North America. Their joint portfolio spans much of the battery production value chain.
Dry coating for improved efficiency
Dürr’s X.Cellify DC product family implements the “Activated Dry Electrode” process developed by LiCAP Technologies. Instead of slurry, a dry-mixed powder is pressed into a free-standing film and laminated onto the collector foil. This eliminates drying, solvent recovery, and treatment, lowering energy and space needs. Excess material can be recycled back into production before lamination, improving efficiency.
A recent proof of concept demonstrated consistent quality with this process, and Dürr reports that it is now seeking pilot partners.
Cell assembly and electrolyte filling
GROB’s new Z-folder integrates the notching process to reduce footprint while maintaining high system stability. Electrodes are fed with low web tension and buffered in a magazine system designed for high availability.
Dürr has also developed a process for high-pressure electrolyte filling, introducing the electrolyte at up to 30 bar in a single step. This approach enables more precise dosing and shortens both filling and wetting times compared to conventional methods.
Digitalization and wet coating updates
The concept factory integrates digital twins to simulate production processes during the planning phase. Data from the simulation connects to Dürr’s MES/MOM software (iTAC) for production control, traceability, and quality analysis.
In parallel, Dürr has introduced updates to its wet coating equipment. These include automated slot die control for more uniform layer thickness, faster start-up, and reduced scrap rates. Laser dryers are also being used to increase web speed and energy efficiency.
The concept factory will be presented as a 3D model at Dürr and GROB’s joint booth during The Battery Show.
Filed Under: Batteries, Technology News