Revolution in battery technology: Dresden discovers environmentally friendly electrodes!

Revolution in battery technology: Dresden discovers environmentally friendly electrodes!

Prof. Stefan Kaskel from the Technical University of Dresden (TUD) together with Dr. Benjamin Schumm and Dr. Holger Althues from the Fraunhofer Institute for Materials and Beam Technology IWS has developed a groundbreaking process for producing battery electrodes: the patented DRYtraec® technology. This cost-efficient and environmentally friendly method was awarded the Joseph von Fraunhofer Prize 2025 at the Fraunhofer Annual Meeting on June 4, 2025. The technology contributes significantly to the sustainable production of lithium-ion batteries (LIB), which are essential for electrified vehicles and stationary energy storage.

DRYtraec® is based on an innovative process that avoids the use of toxic solvents and eliminates the need for energy-consuming and costly drying of the electrode coating. The electrodes consist of a metal foil covered with a thin layer containing active components for energy storage. In the DRYtraec® process, a dry powder mixture is mechanically applied to the film, and both sides of the film can be coated in one step. This leads to powerful, long-lasting and resource-saving electrodes.

Sustainability in battery production

The first prototype system for DRYtraec® was put into operation in 2013 and has been continuously developed since then. The system enables continuous process control and produces high-quality electrodes in the roll-to-roll process. Dr. Holger Althues emphasizes that the platform serves researchers and industrial customers from testing to commercial use. This close collaboration between TUD and Fraunhofer IWS is seen as the key to the successful development of the technology.

A crucial aspect of DRYtraec® technology is saving energy costs and avoiding toxic solvents, which is particularly relevant given the constantly growing demand for environmentally friendly production methods in Germany. The automotive industry has launched ambitious electric vehicle programs, leading to increasing demand for battery manufacturing. Many German companies are currently purchasing battery cells from Asian manufacturers who have decades of experience in mass production.

Environmental awareness and alternative technologies

The increasing demand for sustainable battery technologies is also driven by growing environmental awareness and the need to find alternatives to traditional lithium-ion products. The scarcity of lithium raw materials and the ecological risks of raw material extraction require not only lithium-ion batteries but also alternative technologies, such as zinc and sodium-based systems. These are not only cheap and non-toxic, but can also be integrated into existing manufacturing processes.

Given the challenges associated with the production of lithium-ion batteries, water-based over solvent-free manufacturing processes are critical. These could not only reduce costs, but also significantly reduce CO2 emissions. Zinc and sodium are sufficiently available and do not pose any health risks. It is important to consider these new methods for online battery health analysis to develop sustainable operating strategies. Innovative technologies such as dynamic impedance spectroscopy and AI methods offer promising approaches for future data analysis.

Overall, the development of DRYtraec® not only shows the progress in electric battery production, but also how important sustainable approaches are in modern technology. The industry is at the beginning of a change that affects both production methods and the materials used.