The project aimed to advance lithium‑ion battery technology for electric vehicles by increasing energy density, improving fast‑charging capability, and reducing costs. The research focused on high‑capacity electrode materials, notably nickel‑rich layered oxides (NMC622) for the cathode and silicon‑containing graphite composites for the anode, exploiting silicon’s 4200 mAh g⁻¹ specific capacity versus graphite’s lower value. Electrode fabrication targeted areal capacities above 4 mAh cm⁻², achieved through high active‑material loading, minimal binder and current‑collector fractions, and dense calendaring to reduce inactive pore volume. The resulting reference cells, built from these electrodes, exhibited areal energy densities of roughly 1800–2200 Wh l⁻¹ at low C‑rates (≈ 1/10 C). However, when charged at 3 C (≈ 20 min to 80 % SOC), the energy density fell to about 35 % of the low‑rate value, illustrating the trade‑off between high energy and fast‑charging performance.

To quantify and improve fast‑charging behavior, two experimental protocols were employed. The first used a three‑electrode pouch cell with a lithium reference, allowing direct measurement of the anode potential versus Li and the time required to reach 80 % SOC under controlled current. The second derived a charge profile from cyclic voltammetry, discretized into multiple constant‑current steps and corrected for safety to avoid lithium plating. Both methods revealed that laser‑ablation of the surface binder and micro‑structuring of the electrode surface reduced the time to 80 % SOC by up to 15 % compared with unstructured controls. Electrochemical impedance spectroscopy (EIS) of the anode and cathode showed reduced charge‑transfer resistance after structuring, while Raman spectroscopy confirmed the preservation of the silicon‑graphite composite’s crystalline structure. Scanning electron microscopy and focused ion beam imaging revealed a more uniform current‑collector interface, and micro‑structural modeling with GeoDict quantified a decrease in tortuosity and an increase in the relative diffusion coefficient, correlating with the observed performance gains.

The project’s collaborative framework involved several German institutions. The Zentrum für Sonnenenergie und Wasserstoff (ZSW) produced the high‑loading electrodes and performed pilot‑scale coating, while the Hochschule Aalen (HSAA) conducted laser and micro‑structuring experiments and provided analytical support. Volkswagen (VW) supplied electrodes specifically designed for laser structuring and delivered them to HSAA for further processing. The reference cells were assembled and tested in a dedicated laboratory, and data were shared across partners to refine electrode formulations and cycling protocols. The work was carried out over a multi‑year period, with distinct work packages (AP1–AP5) covering material development, electrode fabrication, cell assembly, electrochemical testing, and industrialization planning. Funding was provided through a German research program focused on advanced battery technologies, enabling the integration of academic research with industrial partners to accelerate technology transfer. The project’s outcomes include validated electrode designs with improved fast‑charging characteristics, a scalable manufacturing pathway, and a set of performance metrics that demonstrate the feasibility of high‑energy, fast‑charging lithium‑ion cells for future electric vehicles.