Reducing Costs and Maximizing Efficiency in Solid-State Lithium Battery Production: A Roll-to-Roll Processing Approach

Abstract

Solid-state batteries (SSBs) represent a transformative leap in energy storage, offering significant advantages in safety, energy density, and environmental impact compared to conventional lithium-ion batteries (LIBs). However, the high costs and complex manufacturing processes of SSBs hinder their large-scale adoption. This research evaluates cost-reduction strategies and efficiency enhancements in the production of SSBs, focusing on roll-to-roll (R2R) processing. Key innovations include the integration of infrared (IR) drying systems and automated start/stop control mechanisms, combined with iterative machine calibration for quality control. The results demonstrate energy savings of ~50%, processing speed improvements of 20–50%, and manufacturing cost reductions of ~20%. These findings contribute to the broader adoption of SSB technology, paving the way for a sustainable energy future.