Smart Three-dimensional ELectrode Lithium-ion batteries with Automated Robotics (STELLAR)

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The UK will ban the sale of new combustion-engine vehicles by 2030 and its aiming to be carbon neutral by 2050. The mass introduction of zero emission vehicles is gradual but irreversible. Electric cars overwhelmingly rely on battery technology. Therefore the UK must be at the forefront of design and manufacture of EVs and batteries. Consumer concerns are around cost, charging time, battery life and limited driving range, which severely impedes the sales of EVs. As such the UK is in urgent need of highly innovative solutions that can (i) overcome the aforementioned concerns and (ii) take a technological lead that generates employment and market competitiveness within a short timeframe. It will need better battery design and manufacturing to produce complex technologies at low cost that the market demands.The Stellar project addresses these challenges by providing innovative and scalable solutions. The project will utilise technology developed by partners for 3D electrode fabrication that has shown significant battery performance improvements. Modelling battery geometries and AI battery design will help address the thermal, energy density and mechanical issues that plague state-of-the-art batteries. This enables vertical integration into the cell manufacturing process through tailoring batteries for specific type of vehicles: fast charging times, increased energy density and power density can then all be engineered before fabrication. CPI will enable fabrication of 3D electrodes designs with optimised ink formulations for commercial applications using state-of-the-art robotic systems for rapid formulation and screening. UKBIC will provide input for ensuring industrial scalability. The process will be able to use AI design to create entire batteries with new electrode geometries and an automated process that allows rapid and cost effective development. The project will demonstrate significant improvement in performance of high-energy lithium-ion battery cells in charging/discharging behaviour and cycle life.Additionally, the project approach requires no change to existing battery facilities, supply chains and represents a 'drop-in' solution whereby 3D electrodes can be supplied to a variety of facilities. We also remove time-consuming manufacturing processes where several iterations are required for optimum structure and ink creation. We aim to improve cell performance and manufacture, enhancing UK capabilities and creating resilience of supply. We will save time and cost from the present manufacturing chain while benefitting environmentally from longer lifetime cells that will help the UK grid in its transition to cleaner energy mixes.