Revolutionizing battery production: Volkswagen and K&B leverage printing technology

By Team IO

PowerCo, a Volkswagen subsidiary, is partnering with German printing machine specialist Koenig & Bauer to develop a groundbreaking Dry Coating technology for battery cell production. This innovative process is expected to reduce energy consumption by 30%, save floor space by 15%, and cut costs by hundreds of millions of Euros annually. The Dry Coating procedure applies powdery materials directly onto foils, creating a thin and even layer that enhances energy density, battery performance, and fast-charging capabilities. The technology also eliminates the need for energy-intensive drying furnaces, suction systems, and chemical solvents.

Collaboration for sustainable battery cell production

According to a recent cooperation agreement signed by Koenig & Bauer and Volkswagen subsidiary PowerCo SE, the two companies will collaborate in the field of sustainable battery cell production. Koenig & Bauer will develop a machine for the industrial powder coating (solvent-free dry coating) of electrodes, a sub-process of multi-stage battery cell production. This new method eliminates the costly and energy-intensive drying of wet-coated electrodes, increasing efficiency and sustainability in volume battery cell production. The development phase is scheduled to run until the end of 2024.

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If the ambitious development goals are achieved, Volkswagen will have the exclusive right to use or sell the Koenig & Bauer equipment for a period of 7 years. A separate supply and distribution agreement will be concluded for this purpose. The collaboration with Koenig & Bauer allows PowerCo to adjust its plants to new processes quickly. The Dry Coating procedure is expected to be a game changer in battery cell production.

Tesla’s promise to produce 4680 batteries that are 50% cheaper has yet to materialize due to challenges with dry electrode coating production. However, Volkswagen may beat Tesla to the punch, with dry-coated cathodes developed through their partnership with Koenig & Bauer.

Impacts of Dry Coating technology

The Dry Coating procedure involves applying powdery basic materials directly onto foils, resulting in a thin and even layer that improves energy density, battery performance, and fast-charging ability. This new process eliminates the need for the most energy-intensive part of cell manufacturing and the use of chemical solvents. Internal tests have already proven successful, showing a decrease in energy consumption of about 30%.

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Furthermore, the technology reduces the required floor space by 15%, eliminates the need for energy-intensive drying furnaces and suction systems, and cuts costs by hundreds of millions of Euros annually. PowerCo and Koenig & Bauer aim to exit the development stage by the end of 2024 and start production in 2026/2027.