On September 9, 2026, Fraunhofer ISE said that, together with partners from research and industry, it has modified battery electrode structures to increase cell energy storage by 10% to 15% at the same weight. The approach relies on significantly thicker electrode coatings, which the institute said can more than triple the thickness used in conventional designs. By increasing the coating thickness, the number of current collectors inside the cell is reduced, leaving more space for active material and improving energy density.
According to Fraunhofer ISE, the team expanded electrode coating thickness from the commonly used range of 100 to 200 micrometers to as much as 800 micrometers. The new architecture was first validated in laboratory-scale zinc-ion, sodium-ion, and lithium-ion cells. In the case of lithium-ion batteries, the researchers also produced pouch cell prototypes on a semi-automated production line at the Fraunhofer ISE Battery Materials and Cell Production Lab in a cleanroom environment.
The institute said the concept is designed with industrial production in mind. The electrodes are PFAS-free and are manufactured without toxic solvents. Compared with a state-of-the-art wet-coating process, the proposed electrode production line is described as less complex, with lower capital, operating, and space requirements. Fraunhofer ISE said this could be particularly relevant for small and medium-sized enterprises considering battery cell manufacturing in Germany.
The project includes industry and academic partners, among them Helmut Hechinger GmbH & Co. KG, acp systems AG, the University of Stuttgart’s Institute for Photovoltaics, and the Karlsruhe Institute of Technology/Helmholtz Institute Ulm. Fraunhofer ISE said the work was carried out through the VORAN, INFAB, and WinZIB2 projects, with public funding from the German ministries supporting the research. The institute said the results represent a promising step toward industrializing the new electrode and cell design for stationary storage and other battery applications.
Source: Fraunhofer ISE
