Solid-state batteries (SSBs) are considered a safer and potentially more energy-dense alternative to traditional liquid electrolyte-based batteries. However, their production remains costly, with current estimates exceeding $100/kWh. This is largely due to the expensive material processing requirements and the low-throughput manufacturing methods currently in use.
Image Credit: sommart sombutwanitkul/Shutterstock.com
This article will explore some of the most recent advances in SSB fabrication, emphasizing the keen role that artificial intelligence (AI) and advanced automation are having on the increasing demand for energy storage and how these technologies are accelerating the path to commercialization and large-scale production. Along the way, we'll discuss:
- How SSBs are typically made
- The role AI and automation play in this process
- Commercial insight into the role of automation in SSB manufacturing
Get instant access to the full article in PDF format—download now and keep it handy for future reference!
How are Solid-State Batteries Typically Made?
With the growing demand for more efficient and safer energy storage solutions, SSBs are emerging as a promising alternative to traditional lithium-ion batteries. These next-generation batteries replace the liquid or gel electrolytes found in conventional designs with a solid electrolyte, which enhances performance, safety, and durability.
With the potential to store more energy, function at higher temperatures and voltages, and reduce the risk of fires, SSBs are gaining significant attention in the battery industry.
However, when it comes to the manufacturing process, making solid-state batteries isn’t exactly simple.
The process begins with cathode production, which is pretty similar to what’s done for lithium-ion batteries—melting LCO granules in an extruder. Meanwhile, the solid electrolyte, like LLCO, is prepared in another extruder. Then, a double extruder layers on the liquid cathode, followed by the liquid electrolyte, onto a current collector film. After that, the coated film is calendered to compress and bond everything together. Finally, the battery cells are cut to size and stacked to form a finished unit.
Yet, despite their potential, SSBs still are not market-ready. One major roadblock is scalability—it’s tricky and expensive to produce solid electrolytes at scale, which makes it hard to compete with well-established lithium-ion tech.
The manufacturing process is more complex and costly, and ensuring the solid parts maintain good contact over the battery’s lifespan is another challenge. Plus, existing production equipment needs modifications to handle SSBs, adding even more hurdles. Material issues, like the brittleness of some solid electrolytes (think oxides and sulfides), also limit packaging options.
Because of these challenges, solid-state batteries aren’t expected to hit the mainstream until at least 2030. But the industry isn’t sitting still—ongoing research and innovation are pushing things forward. AI and automation are playing a growing role in making production more efficient, helping to scale things up and fine-tune performance. With these advances, solid-state batteries could eventually become the go-to solution for next-gen energy storage.
The Role of AI and Automation in SSB Fabrication
Building upon these challenges, the role of AI and automation in SSB manufacturing is becoming increasingly crucial in accelerating their time to market. AI is playing a significant role in materials discovery and design.
For example, Microsoft and the Pacific Northwest National Laboratory recently used AI to identify a promising new solid-state electrolyte in just 80 hours, a process that traditionally takes years. IBM’s Research Lab in Almaden is also leveraging AI to streamline the discovery and optimization of electrolyte materials by integrating automated simulations with purpose-built AI models.
AI-powered systems are also revolutionizing battery design. LG Energy in South Korea has developed an AI model that generates tailored battery designs for industrial customers in a single day, significantly reducing the previous two-week process. Virtual development using AI simulations allows engineers to evaluate different chemistries' impact on performance, safety, and aging without costly physical testing, potentially speeding up battery design by 2-3 times.
In manufacturing, AI and automation are key to scaling up SSB production. Technologies like computer vision, machine learning, and big data analytics are improving precision in material handling, maintaining strict environmental controls, and enabling process automation.
Advanced robotic systems equipped with precise sensors are also working to ensure optimal thickness and uniformity while minimizing waste. Automated systems operating in controlled environments, such as glove boxes or dry rooms, can also be seen to reduce the risk of contamination and maintain high purity standards.
AI is also enhancing Battery Management Systems (BMS), allowing for more accurate battery state estimations, better performance, and predictive maintenance. AI-driven BMS can determine optimal charging patterns, extend battery life, and detect safety issues such as thermal runaway before they become critical.
While challenges remain—such as achieving energy densities above 500 Wh/kg and ensuring long cycle lives—ongoing advancements in AI and automation are expected to drive further innovation. As these technologies continue to evolve, they could significantly shorten the commercialization timeline for SSBs, potentially bringing widespread adoption forward from the projected 2030 timeframe.
Automation in Solid-State Battery Manufacturing
As demand for SSBs grows, manufacturers are adopting automation to improve efficiency and scalability.
KUKA, for instance, has established itself as a leader in automation, offering end-to-end manufacturing solutions that tackle the complexities of SSB production. Its integrated systems bring together precision laser machining, advanced welding technologies, and sophisticated inspection protocols to ensure each battery component meets exacting standards.
By leveraging smart robotics, KUKA helps manufacturers significantly reduce cycle times, lower operational costs, and maintain exceptional quality control throughout the production process.
Complementing KUKA’s approach, Comau has developed specialized robotic solutions tailored for cleanroom battery cell assembly. Their Racer-5SE robot enhances precision manufacturing by enabling highly repeatable processes in environments where contamination control is critical. These compact, high-speed robots provide manufacturers with exceptional flexibility, allowing for quick adaptation to evolving battery designs and industry standards with minimal reconfiguration.
Innovative companies like Maxell are pushing automation further by integrating all-solid-state battery technologies directly into industrial manufacturing. Their solutions prioritize reduced maintenance, increased productivity, and the development of maintenance-free robotic and servo systems that benefit from the superior thermal and longevity characteristics of solid-state batteries.
Real-world applications showcase the impact of these automation technologies. Lion Electric, for example, has successfully scaled its battery production using FANUC robots for material handling and complex assembly operations. Meanwhile, IPLUSMOBOT has deployed autonomous mobile robots to optimize material transfer and logistics within battery production facilities, creating more efficient and adaptable manufacturing environments.
Looking ahead, the future of SSB manufacturing automation will likely be shaped by increasingly sophisticated technologies. AI-driven process optimization, advanced sensor integration, collaborative robotics, and digital twin technologies will further enhance how solid-state batteries are designed, produced, and deployed. These innovations promise to boost manufacturing efficiency while accelerating the global shift toward advanced energy storage solutions.
With demand soaring for electric vehicles, renewable energy, and consumer electronics, automation isn’t just an advantage—it’s a necessity. By tackling today’s production challenges with smarter, more flexible manufacturing strategies, the industry is setting the stage for a more sustainable and high-tech energy future.
Challenges and Future Directions
While robotics and automation bring significant advantages to SSB manufacturing, integrating these technologies comes with its own set of challenges. One of the biggest hurdles is handling advanced materials—many solid-state electrolytes are brittle, sensitive to moisture, or require highly controlled environments. Robotic systems must be precise enough to manipulate these materials without compromising their integrity while maintaining efficiency at scale.
Another challenge is ensuring compatibility with existing manufacturing processes. Many battery production facilities were designed for traditional lithium-ion cells, meaning retrofitting them for solid-state technology can require major investments in infrastructure and process modifications. Manufacturers must strike a balance between leveraging new automation solutions and maintaining cost-effectiveness during the transition.
Flexibility is also a key consideration. Battery designs are evolving rapidly, driven by the demand for higher energy density, improved safety, and faster charging capabilities. Automation systems must be adaptable enough to accommodate these changes without frequent and expensive reconfigurations. This is particularly crucial for manufacturers that serve multiple industries, such as electric vehicles, consumer electronics, and renewable energy storage, where battery requirements can vary significantly.
Looking ahead, future advancements in automation will likely focus on increasing adaptability and intelligence in robotic systems. More sophisticated machine learning algorithms could enable real-time process adjustments, improving quality control and reducing material waste. Enhanced sensor technologies may allow robots to detect minute defects or inconsistencies in battery components, further boosting reliability.
Collaborative robotics (cobots) will also play a bigger role. These robots, designed to work safely alongside human operators, could bring more flexibility to battery production lines. Instead of completely replacing human labor, cobots could assist with intricate assembly tasks, material handling, and quality inspection—improving efficiency while maintaining the precision required for SSB manufacturing.
Ultimately, overcoming these challenges will be essential for the widespread adoption of solid-state batteries.
Want to Learn More?
Solid-state battery production is changing fast, and automation is playing a huge role in making it all possible. If you’re curious about where things are headed, here are some interesting areas to explore:
Download the full article now and keep a PDF copy for easy access anytime!
References and Further Reading
- Zaman, W., & Hatzell, K. B. (2022). Processing and manufacturing of next generation lithium-based all solid-state batteries. Current Opinion in Solid State and Materials Science, 26(4), 101003. DOI:10.1016/j.cossms.2022.101003. https://www.sciencedirect.com/science/article/abs/pii/S1359028622000237
- Sharma, A. et al. (2020). Enabling the Electric Future of Mobility: Robotic Automation for Electric Vehicle Battery Assembly," in IEEE Access, vol. 7, pp. 170961-170991. DOI:10.1109/ACCESS.2019.2953712. https://ieeexplore.ieee.org/document/8902005
- Despeisse, M. et al. (2023). Battery Production Systems: State of the Art and Future Developments. IFIP Advances in Information and Communication Technology, vol 692. Springer, Cham. DOI:10.1007/978-3-031-43688-8_36. https://link.springer.com/chapter/10.1007/978-3-031-43688-8_36
- Automate battery production with robotics and proven solutions. KUKA AG. https://www.kuka.com/en-us/industries/battery-production
- Tronzano, G. C. (2024). Navigating the Electric Mobility Path with Solid-State Batteries. Machine Design. https://www.machinedesign.com/mechanical-motion-systems/article/55126965/comau-navigating-the-electric-mobility-path-with-solid-state-batteries
- All-solid-state batteries | Applications and collaborations case studies | Rechargeable Batteries | Biz.maxell - Maxell. https://biz.maxell.com/en/rechargeable_batteries/assb-solutions-robot.html
- Robotic Automation Speeds Up Lion Electric’s EV Battery Production. Fanuc America. https://www.fanucamerica.com/case-studies/the-lion-electric-company
- Application of Autonomous Mobile Robots (AMRs) in the Front Section of Lithium Battery Factories. IFR International Federation of Robotics. https://ifr.org/case-studies/application-of-amrs-in-the-lithium-battery-factories
- Fremont Factory. Tesla. https://www.tesla.com/fremont-factory
Disclaimer: The views expressed here are those of the author expressed in their private capacity and do not necessarily represent the views of AZoM.com Limited T/A AZoNetwork the owner and operator of this website. This disclaimer forms part of the Terms and conditions of use of this website.