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arXiv · 2506.17048

Opportunities for real-time process control of electrode properties in lithium-ion battery manufacturing

Noël Hallemans·Philipp Dechent·David Howey·Simon Clark·Mona Faraji Niri·James Marco·Patrick S. Grant·Stephen R. Duncan
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Abstract

Lithium-ion batteries (LIBs) have an important role in the shift required to achieve a global net-zero carbon target of 2050. Electrode manufacture is amongst the most expensive steps of the LIB manufacturing process and, despite its apparent maturity, optimised manufacturing conditions are arrived at by largely trial and error. Currently, LIB manufacturing plants are controlled to follow the fixed "recipe" obtained by trial and error, which may nonetheless be suboptimal. Moreover, regulating the process as a whole to conform to the set conditions is not widespread. Inspired by control approaches used in other film and sheet processes, we discuss opportunities for implementing real-time process control of electrode-related products, which has the potential to reduce the electrode manufacturing cost, CO2 emissions, usage of resources by increases in process yield, and throughput. We highlight the challenges and significant opportunities of implementing real-time process control in LIB electrode production lines.

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Noël Hallemans, Philipp Dechent, David Howey, Simon Clark, Mona Faraji Niri, James Marco, Patrick S. Grant, Stephen R. Duncan. 2025-06-20. Opportunities for real-time process control of electrode properties in lithium-ion battery manufacturing. https://arxiv.org/abs/2506.17048

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