Battery manufacturers are entering an era of rapid evolution, with 2025 set to bring significant advancements in materials and production methods. However, this progress comes with intense competition to provide the most cost-effective batteries.
One crucial area that demands attention is improving battery powder handling. Situated at the beginning of the manufacturing process, it plays a pivotal role in the final battery's efficiency, quality, and performance.
The Shift to Dry Electrode Processing (DBE)
The transition to dry electrode processing is among the industry's most notable trends. Traditionally, electrode production methods have relied heavily on expensive extraction and recovery systems needed to handle toxic solvents. However, companies are now realising the benefits of dry electrode processing as an alternative.
Tesla's Influence
Tesla acquired Maxwell Technologies to leverage the dry battery electrode (DBE) process for producing large cylindrical batteries such as the 4680. This dry electrode process offers several advantages, including low energy requirements, a smaller factory footprint, and reduced production costs. If applied to both electrodes, it could significantly lower costs, benefiting both EV manufacturers and production companies.
Tesla is producing 4680 cells with dry-coated electrodes at its Gigafactory in Austin, Texas, where the Model Y and Cybertruck are being manufactured. Although the dry coating process has not yet been completed at the required scale, several other companies, including Panasonic, LG, CATL, EVE, BAK, and SVOLT, have begun developing and mass-producing 4680 cells.
DBE Global Momentum
The 4680 trend is gaining momentum globally, with announcements from companies like BMW, Apple, Lucid, Rivian, Xiaopeng, NIO, FAW, JAC Motors regarding their adoption of 4680 batteries. According to SNE Research, the demand for xEV 4680 cells is projected to be approximately 72 GWh by 2025 and around 650 GWh by 2030. For Tesla, it's estimated to be around 80 GWh by 2025, with BMW at 59 GWh and other companies at approximately 44 GWh.
Elon Musk has announced plans to produce their 4680 dry cathode batteries at an impressive 72 GWh by 2025, scaling to 650 GWh by 2030. In Japan, Panasonic will soon start mass production of its new 4680 batteries, which boast a volume and capacity five times greater than conventional cells for electric cars.
Dry Electrode Technology
Dry battery electrode technology offers a cutting-edge alternative in the battery industry. Compared to traditional wet coating methods, it utilises a powder-to-film process that saves time, energy, and space, offering advantages over conventional methods in terms of both production and performance.
One such innovative process within dry electrode processing is fibrillization or fibrillation. This employs binders like PTFE to produce fine filaments that bond active electrode materials without solvents. The resulting mixture is hot-rolled into a film and laminated with the current collector, streamlining manufacturing processes and reducing production costs.
Matcon's high-shear blender can play a crucial role in this process, providing manufacturers with a distinct competitive edge by eliminating the need for solvents and reducing cost and complexity.
Contact us to find out more about this process. Furthermore, we also offer this functionality in pilot scale, thanks to our high-shear pilot-scale blender.
The Rise of Iron Phosphate (LFP) Chemistry
As we move towards 2025, the industry is increasingly converging towards iron phosphate (LFP) chemistry. Companies that gamble on the wrong chemistry without the flexibility to pivot their production capabilities risk falling behind.
However, even for companies already achieving a solid product-market fit, the scaling-up process remains a fundamental challenge, creating many unforeseen bottlenecks. Addressing these material handling and processing bottlenecks will be crucial for optimising production scalability, ensuring consistent quality, and maintaining cost-effectiveness in the battery industry landscape.
Addressing Scale Challenges in Material Handling
In material handling, difficulties often arise when managing hundreds or thousands of kilograms of product within a single container, whether a bulk bag or an Intermediate Bulk Container (IBC). At this scale, getting the powders out of the container and feeding them to the next process can pose significant challenges, potentially affecting the quality and efficacy of the finished battery.
Other potential issues to consider:
Managing Contamination and Moisture Ingress
Excessive moisture during battery production can cause corrosion and reduce performance. It can also accelerate material degradation and shorten the lifespan of the final product. To maintain the integrity of battery powders, Matcon has developed gas-inerting powder handling techniques using gases such as Nitrogen or Argon. This approach minimises the risk of moisture ingress by creating an inert atmosphere that prevents the interaction of sensitive materials with oxygen and water vapour. Furthermore, Matcon's advanced sealing and monitoring systems further enhance protection against environmental factors, enabling manufacturers to sustain optimal conditions throughout the production process. These measures can make a huge difference in maintaining the quality and reliability of batteries in high-volume, scalable manufacturing settings.
Bridging and Rat-holing
Battery powders display a wide range of properties, and as powder chemistries advance, their characteristics can shift, often resulting in stickiness and poor flow. Matcon technology is renowned in the manufacturing industry for its expertise in ensuring consistent flow control of these powders.
Ensuring Homogeneity in Large-Scale Handling
Achieving homogeneity across powder batches ensures that each production unit meets rigorous quality and performance standards. This consistency builds trust in the manufacturing process and the final battery products.
Handling Hot Powders Efficiently
In response to feedback from leading manufacturers, we have pioneered an advanced Intermediate Bulk Container (IBC) and Discharge Station specifically capable of managing powders at temperatures up to 200°C. This innovative design allows for the direct collection of hot powders from furnaces, reactors, and jet mills, facilitating their discharge into downstream processes without the necessity for substantial cooling measures. Manufacturers can achieve significant capital (CAPEX) and operational expenditure (OPEX) savings by minimising the need for extensive cooling equipment.
Conclusion
The electric vehicle (EV) market is dominated by a concentrated group, with major players like CATL, BYD, and LG Chem controlling a substantial portion of the market share. According to
SNE Research, only nine companies account for 90% of the battery supply.
This competitive landscape is further illustrated by the resources invested by these titans; for instance, CATL boasts an impressive 18,000 employees dedicated to Research and Development, contrasting sharply with other companies like Northvolt, for example, whose total global workforce of just 6,000.
For other manufacturers aiming to penetrate this formidable market, the path to success hinges on a blend of innovation and implementing an ultra-efficient manufacturing system. By partnering with Matcon, companies can leverage cutting-edge powder handling technology to gain a competitive advantage and ensure that they meet the demands of scalability and quality.
Contact us to learn more about our solutions and how we can help you optimise your production processes for success.
