High-Performance Battery Manufacturing

In today’s competitive battery market, innovators need a more advanced strategy than a hands-on trial-and-error development approach. This session introduces the Siemens Xcelerator portfolio—a suite of software tools that leverages generative engineering and digital twins to help battery developers reduce prototyping costs and streamline scale-up. Discover how integrated simulation and data management shorten time-to-market while ensuring consistent quality at every stage—from materials research through full-scale battery production.

GenX is a Generative AI tool that simulates rare defects and generates synthetic defect images for enhanced AI-powered visual inspection in manufacturing. While traditional AI inspection systems need hundreds to thousands of real defect samples for training—a time-consuming and costly process—GenX eliminates this data bottleneck. By creating high-fidelity synthetic defect images from as few as three real defect samples, it dramatically reduces training time, improves AI accuracy, and accelerates model deployment. In this speech, Keven Wang will share GenX's key technological innovation, industrial applications, and its economic impact that GenX offer to the industries and business.

Solid Energies Inc. (SEI) is presenting a new generation of solid-state Lithium-air batteries (SSLaBs), a new class of beyond-Li technology, which is expected to provide superior safety and extremely high energy densities (1000 WH/kg, four times the current Li-ion batteries). The presentation will review (1) SEI’s advances in polymer composite electrolytes, a novel cell structure design, and a highly efficient manufacturing process, and (2) the development work on SSLaB having been conducted, which covers the optimization, scaling-up, and progress directed from technical feasibility demonstration to engineering prototypes toward the establishment of a pilot-scale line for commercial scale manufacturing.

Since our inception, we have continued to provide integrated solutions from design to mass production, leveraging our expertise in lithium-ion technology. Beff Navigator, which accelerates the development of lithium-ion battery materials and cells, is an innovative software that enables a rapid end-to-end process—from concept creation and specification design to prototyping, testing, and validation—supporting customers in bringing their products to market faster. In addition, our team of professional battery engineers provides expert support, allowing for the creation of more precise specifications, high-quality prototyping and testing, and advanced analysis of results. Beff Navigator provides integrated solutions from design to mass production.

Lithium manganese iron phosphate (LMFP) is attractive as a lithium-ion battery cathode material as it does not contain Ni and Co, which are supply-constrained and expensive. However, widespread use of LMFP has been limited for reasons that include battery cycle life. In this presentation we will discuss insights from experiments being conducted using LMFP cathodes. Performance characteristics such as capacity fade and impedance changes during battery aging will be discussed.

Battery systems have evolved into highly complex assemblies where the battery cell, while central, is only one part of a larger integrated system. Battery systems incorporate mechanical structure, thermal management, and advanced battery management systems (BMS), requiring robust integration to deliver safety, reliability, and performance. This presentation will explore the current state of the industry, examining how each subsystem contributes to the overall performance of the battery system. We will examine emerging trends, technological advancements, and opportunities for innovation in next-generation systems.

Polyolefin separators can undergo oxidation at high voltage, therefore the base film is typically coated on one or both sides with ceramic particles. While ceramic-coated separators are commonly used in EV applications, ENTEK will discuss the structure-property relationships of (1) ceramic-filled separators in which the ceramic is distributed throughout the bulk PE structure and (2) coextruded separators with a ceramic filled layer(s) combined with the PE layer.

The application of the superbatteries and advanced supercapacitors in plug-in hybrid electric vehicles (PHEVS) and fuel cell electric vehicles (FCVEV) have studied via ADVISOR vehicle simulations. Results will be given for energy storage requirements (kWh), 0-60 mph acceleration times, and differences in energy consumption (Wh/mi) on driving cycles using Lithium batteries, advanced supercapacitors, and superbatteries.

This presentation will address the safety behavior and underlying mechanisms of SSBs, with direct comparison to liquid-state batteries (LSBs). Testing results show that, during internal shorts in high-energy systems, the severity of fire and explosion follows the order: SSB > LSB. The data indicate a counterintuitive trend — the greater the liquid content in the battery, the safer its behavior under abuse conditions.

Electrolyte innovation is critical to unlocking the performance and safety of next-generation lithium-ion batteries. This presentation will explore recent progress in electrolyte raw materials, advanced formulations, and scalable manufacturing solutions. Emphasis will be placed on addressing emerging performance demands, including compatibility with silicon anodes, Mn-rich and high-nickel cathodes, li-metal, fast charging, reduced gassing, and high-temperature stability. The session will highlight how material and process development can enable evolving industry needs.

As many battery startups move from the benchtop to the manufacturing floor, the question remains: How much does it cost to build a battery factory? This presentation will answer that for North America, Europe, and Asia. It will also explore alternative manufacturing models such as contract manufacturing, capital-lite, and zero capex component-as-a-model approaches. Additionally, it will delve into best practices for supply chain procurement for new factories.

Smart 3D Current Collectors are emerging as one of the most impactful breakthroughs in cell architecture - a technology that finally breaks the limitations of today’s flat foils. This session will reveal new data showing how a porous 3D metal structure boosts energy density, charging speed, and manufacturability, including enabling true dry coating. Applicable to any chemistry, this platform opens a scalable path to next-generation, cost-effective batteries and a stronger US supply chain.

Electrochemical impedance spectroscopy is not a new technology by any means in lithium-ion. Using EIS during fast charging as a means of monitoring the cell temperature and providing a robust measurement of plating risks, including feedback across the whole electrode surface, is about to be introduced with NXP’s new eisBMS solution.

As battery and advanced manufacturing projects accelerate across the US, selecting the right site is more critical than ever. This session reveals how to identify locations that combine skilled-labor pipelines tailored to high-tech manufacturing; maximum federal, state, and local incentives to offset capital costs; reliable, renewable, and high-capacity electric infrastructure to power operations; and tariff mitigation benefits through domestic production strategies and Foreign Trade Zones (FTZs). Learn how to align site strategy with strong incentive support, long-term growth needs, and operating resilience.