ZSW Scales Up Cathode Material

October 28, 2026

Source: E & M powernews

A pilot line in Ulm aims to bring new battery materials from the lab into industrial application. This could benefit manufacturers of electric cars and large-scale energy storage systems.

The Baden-Württemberg Center for Solar Energy and Hydrogen Research (ZSW) has brought the “Powder-Up!” pilot line in Ulm into full operation. It enables the production of new cathode materials in the quantities required for the development of large battery cells. The ZSW describes it as the first independent facility of its kind in Germany. It is open to industry and research partners for collaboration.

Cathode materials influence a battery cell’s energy density, lifespan, safety, and cost. New compositions are initially tested in the lab in gram quantities. Larger batches are required for industry-scale cell testing. The pilot line is designed for up to 100 kilograms. The ZSW has already scaled up the first samples from a few grams to around 15 kilograms.

The ZSW is investigating high-energy-density nickel-manganese-cobalt (NMC) cathodes, which are relevant, for example, for electric vehicles with long ranges. The current focus is on lithium iron phosphate (LFP). This cell chemistry does not require nickel or cobalt and is considered comparatively cost-effective, durable, and thermally stable. It is particularly suitable for large-scale stationary storage systems but is also used in electric cars.

The International Energy Agency (IEA) estimates that LFP will account for more than 90 percent of the world’s newly installed stationary battery storage capacity by 2025. For batteries used in electric vehicles, the figure was over 55 percent. The ZSW is already producing LFP material on a kilogram scale. In addition, it is working on cathode materials for sodium-ion batteries, which will also be viable options for stationary storage in the future.

Spanning approximately 2,400 square meters, the facility houses more than 135 systems and devices for synthesis, heat treatment at 600 to 1,000 degrees Celsius, analysis, and quality assurance. Process data is digitally recorded and is also intended to be used for AI-supported development. The ZSW also has facilities for cell manufacturing and battery testing.

The federal and state governments provided approximately 34 million euros in funding for the project. Of this, 24 million euros from the federal government went toward technology and infrastructure, and 10 million euros from the state government went toward the building. The facility was inaugurated in 2024, and commissioning began in March 2025.

The project is also relevant for Europe’s supply chains: According to the IEA, in 2025, approximately 85 percent of the world’s cathode active materials for electric vehicle batteries were produced in China. The Ulm facility facilitates the testing of proprietary manufacturing processes.

Author: Fritz Wilhelm