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The production of lithium‐ion cells consists of a series of highly interlinked process steps. Calendering, as the last step of electrode manufacturing, has a significant impact on electrode characteristics. The process primarily aims at enhancing the electrode energy density and hereinafter, minimizing the plastic deformability, improving the conductivity, and determining the pore structure of the electrode. So far, electrode characteristics are mainly investigated regarding the impact on cell quality. However, they also affect their subsequent processabilities in the process chain, which is crucial for cost improvement, for example, by reduction of scrap rates. Herein, a methodical identification, description, and categorization of electrode characteristics is conducted based on a literature review, an expert survey, and operating experience. The methodical classification will provide a basis for the modeling of the interaction between the influencing factors (product properties, process parameters, and machine characteristics) and electrode characteristics during calendering.

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.

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This manuscript analyzes different scenarios to estimate the manufacturing cost for small-scale and mass production of all-solid-state batteries.

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