All‐solid‐state batteries (ASSB) are promising candidates for future energy storage. However, only a little is known about the manufacturing costs for industrial production. Herein, a detailed bottom‐up calculation is performed to estimate the required investment and to facilitate comparison with conventional lithium‐ion batteries (LIB). Results indicate that sulfide‐based ASSBs can indeed be competitive if the material compatibility issues can be solved and production is successfully scaled. In contrast, oxide‐based ASSBs will probably not be able to compete if cost is the decisive factor. A sensitivity analysis with Monte Carlo simulation reveals that the inert gas atmosphere required for sulfide‐based ASSBs contributes little to the overall cell costs, whereas the sintering step for oxide‐based ASSBs is highly critical. The calculation also indicates that in‐house manufacturing of the lithium anode will be cheaper than purchasing the lithium foil externally if the cell producer has sufficient processing know‐how. Finally, the aerosol deposition method is investigated, revealing that a deposition rate far above 1000 mm3 min−1 would be required to make the technology economically feasible in ASSB production. The results of this study will help researchers and industry prioritize development efforts and push the scale‐up of future high‐energy batteries with improved performance.
Sheet Molding Compound (SMC) materials offer attractive specific strength and stiffness properties. With an addition of short cycle times, the possibility for complex geometries and a high recycling potential, this material is a promising solution for the manufacture of lightweight components of numerous industrial sectors. Accurate and reliable simulation can contribute to a fast and competitive development process and effectively reduce the time-to-market. Especially, the accuracy of the simulative filling process is crucial to be able to predict the mechanical properties and hence, pave the way to structural parts. An appropriate characterization of the rheological behavior is therefore, crucial for accurate simulation results. To this purpose bar flow tests are performed and the experimental results are compared to the numerical results. A sensitivity analysis is performed to investigate the influence of each parameter on the simulation outcome. Furthermore, guidelines to improve the simulation accuracy and the testing equipment are derived. In the testing method some improvement potential was identified and the necessity for a testing method closer to the compression process could be established.
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