Battery research at Fraunhofer ISI

Forecasting Battery Cell Production in Europe: A Risk Assessment Model 

Journal Article in: Batteries 2025, 11, 76. 

The report Benchmarking International Battery Policies: A cross analysis of international public battery strategies focusing on Germany, EU, USA, South Korea, Japan and China presents a comparison of the battery policies of the world's leading countries. The report analyses their political and technical objectives, key performance indicators and funding strategies with a focus on lithium-ion, solid-state and alternative batteries, providing an overview of the status quo and the evolution of the global situation.

The Lithium-Ion Battery Roadmap focuses on the battery industry's scaling activities through 2030 and examines possible technology options, approaches, and solutions in the areas of materials, cells, production, systems, and recycling. The study examines three trends in particular: The production of performance-optimized, low-cost and sustainable batteries.

Solid-state batteries are considered as a reasonable further development of lithium-ion batteries with liquid electrolytes. On the basis of an analysis of all materials and concept options, a roadmap for solid-state batteries is presented, relying on both literature survey and experts' opinions. Diverse cell concepts with different solid electrolytes may be developed up to the commercial level, yet there are still major uncertainties concerning production routes, safety as well as cost. As one of the key developments, it appears that hybrid material and cell concepts may be particularly successful on the way to commercialization.

The Lithium-Ion Battery Roadmap focuses on the battery industry's scaling activities through 2030 and examines possible technology options, approaches, and solutions in the areas of materials, cells, production, systems, and recycling. The study examines three trends in particular: The production of performance-optimized, low-cost and sustainable batteries.

The Roadmap on alternative battery technologies addresses potentials and challenges of alternative battery technologies. It evaluates promising metal-ion, metal-sulfur, metal-air and redox flow batteries based on technical, economic and ecologic aspects for the period until 2045. The roadmap shows: Alternative battery technologies do not offer the same comprehensive fit as lithium-ion batteries but they offer high potential, for example for more sustainability or lower costs and can complement or even replace lithium-ion batteries in certain applications. However, many of the technologies considered still have to overcome a number of challenges before they can enter the market or become widespread.

The Solid-State Battery Roadmap 2035+ considers a wide range of aspects from the individual materials, components and cells through to their utilization. It critically evaluates existing research as well as the latest findings and compares the development potential of solid-state batteries over the next ten years with that of established lithium-ion batteries. The roadmap demonstrates that solid-state batteries have a lot of potential, but will have to prove their commercial viability in the next five years.

The Energy Storage Roadmap 2017 (available in German only) updates all roadmaps developed so far. It addresses the challenges for research and development (R&D) of high-energy batteries, for which cell production capacities are currently being massively expanded worldwide. In addition, long-term potentials for alternative battery technologies show whether and which technologies could enter the market beyond 2030. 

The General Roadmap Lithium-Ionen Batteries 2030 (available in German only) updates and integrates the Technology and Product Roadmap published in 2010 and 2012. It provides a comprehensive overview of the status and development potential of lithium-ion batteries for electromobility and stationary applications and thus forms a bracket around the roadmaps "Energy Storage for Electromobility“ and “Stationary Energy Storage“, which are published in parallel. It outlines the expected developments in lithium-ion battery technology and alternative or competing energy storage solutions up to 2030 and highlights dependencies between technologies for electromobility and stationary applications. Long-term scenarios up to 2050 allow questions of raw material availability, the influence of technical progress of the lithium-ion battery as well as market changes to be considered in a model-based manner. 

In the Technology Roadmap Lithium-Ion Batteries 2030 from 2010 (available in German only), the technological developments of lithium-ion batteries from the material and component level to cell types as well as complementary and competing technologies were recorded and estimated for the period up to 2030. The roadmap has basically retained its validity in terms of statements and time periods up to 2015 and has now been made connectable and differentiated at system and application level. 

The Lithium-Ion Battery Product Roadmap 2030 from 2012 shows the potential applications and specific requirements for lithium-ion batteries for a wide range of applications such as electric two-wheelers, hybrid or purely battery electric vehicles, vans, commercial vehicles or decentralised and centralised stationary applications. The roadmap is still valid and has now been quantified in terms of its range of applications with the “General Roadmap Lithium-Ion Batteries 2030“.

The General Roadmap Energy Storage for Electric Mobility 2030 (available in German only) updates and integrates the Technology and Product Roadmap published in 2010 and 2012. It provides a comprehensive overview of the status and development potential of lithium-ion batteries for electromobility and stationary applications and thus forms a bracket around the roadmaps “Energy Storage for Electromobility“ and “Stationary Energy Storage“, which are published in parallel. It outlines the expected developments in lithium-ion battery technology and alternative or competing energy storage solutions up to 2030 and highlights dependencies between technologies for electromobility and stationary applications. Long-term scenarios up to 2050 allow questions of raw material availability, the influence of technical progress of the lithium-ion battery as well as market changes to be considered in a model-based manner. 

The Technology Roadmap Energy Storage for Electromobilit 2030 from 2012 shows and quantifies essential development paths of future battery systems as well as their performance data and key parameters, in particular service life, quality and safety. The focus of the road map is on the consideration of central energy storage technologies that are considered promising for use in electric vehicles, more precisely plug-in hybrid vehicles (PHEV) and battery electric vehicles (BEV).

The Product Roadmap Energy Storage for Electromobility 2030(available in German only) takes into account BEVs, PHEVs and HEVs, all of which are innovation drivers for the further development of the lithium-ion battery with the highest requirements, especially in terms of battery energy density and cost. BEVs represent by far the most important market for high-energy lithium-ion battery cells. Compared to today's mostly cost-optimised models, the roadmap shows a path for range-optimised and affordable electric mobility for the next 10 to 20 years. To this end, it also identifies and discusses the framework conditions that will promote and hinder this development during this period. 

In the General Roadmap Stationary Energy Storage 2030 (available in German only) the technology offer from the Technology Roadmap is compared with selected applications or business models from the Product Roadmap in which the lithium-ion battery is currently used or can be used in the short to medium term. Compared to the reference technology used today, substitution scenarios are developed that show when an alternative technology can achieve an improvement over the respective status quo. The scenarios considered are (1.) decentralised, grid-connected PV battery systems for self-demand optimisation, (2.) multi-purpose self-demand optimisation with larger storage systems together with peak shaving, as well as (3.) direct marketing of renewable energies (on the generation or grid side, e.g. in island grids) and (4.) balancing power. The comparison of the technologies results in a differentiated picture in which very different technical solutions are attractive. 

Based on today's reference technologies, the Technology Roadmap Stationary Energy Storage 2030 (available in German only) looks at eight classes of storage sizes and typical charging and discharging times to see which alternative technology developments are likely by 2030. With regard to their properties, three technologies are evaluated at three different points in time (current, short-term and medium/long-term): the lead-acid battery as a reference, lithium-based batteries and redox-flow batteries. 

The Product Roadmap Stationary Energy Storage 2030 (available in German only) deals with possible applications, products and business models for the technologies documented in the Technology Roadmap and subdivides them into the local (private, commercial owner-ship), distribution grid and transmission grid level. In addition, framework conditions are discussed that can promote or inhibit the demand for electrochemical energy storage. Based on three specific use cases, (1.) decentralised, grid-connected photovoltaic (PV) battery systems (on-grid PV) for self-demand optimisation, (2.) self-demand optimisation with larger storage units (campus/commercial/industrial) and (3.) industrial peak shaving, requirements for the performance parameters of a technical solution are identified. 

Analysis of development potentials for LIB battery cell formats with respect to active materials, cell design, cell manufacturing and cell safety. Update 2022.

Analysis of the demand for skilled workers by the fast growing European battery industry.

Future Expert Needs in the Battery Sector – March 2021

Summary and clarification of key issues or potential challenges in the market diffusion of battery electric vehicles.

Batteries for electric cars: Fact check and need for action

Analysis of development potentials or optimization possibilities of cylindric, pouch and prismatic cells. (available in German only)

Development Perspectives for Cell Formats of Lithium-Ion Batteries in Electromobility

The VDMA Battery Production Equipment Roadmap 2030 (Update 2023) addresses the further development of production technology. Since its initial publication in 2014, the roadmap has received worldwide attention, and many suggestions have been taken up and implemented. The goal-oriented dialog between battery producers, production research and the mechanical and plant engineering sector was continued, also including experience with foreign competence providers.

The VDMA Roadmap Battery Production Equipment 2030 (Update 2020) (available in German only) addresses the further development of production technology. It discusses upcoming requirements for battery machine manufacturing and formulates approaches to solutions for mechanical and plant engineering. In a total of 14 technology chapters, red brick walls were identified and discussed according to the current state of technology.

The roadmap builds on publications released in 2014, 2016 and 2018.

The VDMA Battery Production Equipment Roadmap 2030 (Update 2018) addresses the further development of production technology. It discusses future requirements for battery machine construction and formulates approaches to solutions for machine and plant construction.

The roadmap builds on publications released in 2014 and 2016.

The VDMA Battery Production Equipment Roadmap 2030 (Update 2016) addresses the further development of production technology. It discusses future requirements for battery machine construction and formulates approaches to solutions for machine and plant construction.

The Background Report on Sodium-Ion Batteries 2023: Status Quo and Perspectives along a Future Value Chain (available in German only) presents current technological developments and challenges on SIB from active materials to cell production and first applications. The report discusses in detail industrial developments in Europe and Asia and presents forecasts for SIB production and application markets. The study is a joint effort of Fraunhofer ISI, Fraunhofer IPT, Fraunhofer FFB and the PEM of RWTH Aachen University. 

Background report on the European battery innovation system 2022

The background report provides an overview of the situation of three important industry groups in the battery innovation system in Europe: material manufacturing and recycling, mechanical and plant engineering, cell manufacturing. The report presents current challenges and compares the R&D offer of the Fraunhofer Research Fabrication Battery Cell FFB. (available in German only)

Consentec; Fraunhofer ISI; Stiftung Umweltenergierecht (2022): Batteriespeicher in Netzen. Final Report on behalf of the Federal Ministry for Economic Affairs and Energy (BMWi). (available in German only)

The Reporting on the Electric Mobility Act (Berichterstattung zum Elektromobilitätsgesetz) (available in German only) accompanies the “Law to prioritize the use of electrically powered vehicles” (Gesetz zur Bevorrechtigung der Verwendung elektrisch betriebener Fahrzeuge) – in short form Electric Mobility Act – enacted by the Federal Government of Germany. The report explains the background of the law, refers to the status quo of electric mobility in Germany and discusses the concrete implementation of the law as well as recommendations for the future. 

The Update of the 2018 Energy Storage Monitoring Study (available in German only) shows that China has become the leading supplier of batteries and the leading market for batteries as well as electric mobility between 2016 and 2018. (available in German only)

The Energy Storage Monitoring-Update 2016 (available in German only) comprises 30 individual indicators distributed across the categories of demand, market structures, industry, and research and technology. The Energy Storage Monitoring 2016 is therefore directly comparable with the Energy Storage Monitoring 2014. 

The Energy Storage Monitoring 2014 (available in German only) comprises 30 individual indicators distributed across the categories of demand, market structures, industry as well as research and technology. 

Journal Article in: Energy & Environmental Science, RSC, Cambridge (2024). Download

The present study Recycling of Lithium-Ion Batteries: Opportunities and Challenges for Mechanical and Plant Engineering aims to quantify these secondary effects of a European recycling industry. To this end, a Fraunhofer ISI market model was used to derive forecasts for the growth of a European battery recycling market. The effects for mechanical and plant engineering were quantified on the basis of interview results with battery recycling and plant experts.

Download quantifying battery recycling (available in German only)

The battery industry faces the challenge of sustainability, encompassing environmental impact reduction, social responsibility, and governance. In Europe, sustainability involves developing an ecosystem that ensures stability and growth across the battery value chain. This includes securing access to critical raw materials and achieving technological sovereignty. Efforts have been made to localize production, explore European raw material deposits, and implement regulations. However, Europe still relies heavily on non-European sources, highlighting the need for more sustainable solutions and reducing dependency on non-European players.

Sustainability pathways in a future European battery ecosystem

The content focuses on the “Prospects for climate-neutral battery production for electromobility in Germany“. Despite the poor availability of data, an attempt is made to provide as comprehensive as possible a picture of the production processes involved in cell manufacture. (available in German only)

Battery Location on a Climate Course 

Forecasting Battery Cell Production in Europe: A Risk Assessment Model 

Zeitschriftenaufsatz in: Batteries 2025, 11, 76. 

Circular battery design: investing in sustainability and profitability 

Journal Article in: Energy & Environmental Science, RSC, Cambridge (2024).

Techno-Economic Suitability of Batteries for Different Mobile Applications—A Cell Selection Methodology Based on Cost Parity Pricing 

Journal Article in: World Electric Vehicle Journal 2024, 15, 401.