Electromobility is a crucial pillar in reducing CO₂ emissions. Currently, lithium-ion batteries are used in the vast majority of electric vehicles, but their lifespan is limited due to aging processes (degradation). Additionally, critical cobalt-containing active materials are often used. Improved and cobalt-free active materials can enhance the lifespan and sustainability of the batteries.

Novel functional coatings for battery powders developed at Fraunhofer IKTS prevent interactions with the electrolyte and thus the degradation of the cells. For this development, the research team was honored by the Federal Ministry for Economic Affairs and Climate Action (BMWK) as the Innovation Project of the Year 2025 in the Industrial Collective Research funding program.

Atomic layer deposition and spray drying as key technologies

Project leader Dr. Mandy Höhn explains: "Our team has succeeded in optimizing cobalt-free and low-cobalt active materials through innovative coating processes such as atomic layer deposition (ALD) and spray drying. We have achieved very promising results that demonstrably lead to more stable behavior of the active materials in the batteries, enabling increased ranges and shorter charging times – an important step for sustainable electromobility!"

For this purpose, on one hand, powdered active materials were optimized with protective coatings, and on the other hand, the electrochemical properties were investigated with varying coating thicknesses. Electrodes were produced from the coated active materials of both processes using a film casting method. The resulting test cells underwent performance and long-term testing. Dr. Kristian Nikolowski, head of cell development and testing, is pleased: "The tests showed very promising results for both processes. We were able to demonstrate a positive impact on rate capability and cycle stability in cell tests with various coated active materials."

Both developed coating processes are scalable to large-scale production and can be implemented cost-effectively. The research results thus provide an important basis for the transfer to the manufacturing of future batteries.

Research for the transfer to industry

Industrial Collective Research ("Industrielle Gemeinschaftsforschung", IGF) is an open-topic and pre-competitive funding program of the BMWK that gives SMEs access to practice-oriented research.

In 2025, the BMWK awarded outstanding research projects in the IGF for the first time to give greater visibility to innovations from all sectors. The project "Functional Coating of Battery Powders" from Fraunhofer IKTS was submitted by the European Research Society for Thin Films e.V. (EFDS).

On March 27, 2025, the IKTS team impressed the expert audience at the Innovation Promotion Congress with their development of functional coatings for battery powders for sustainable and safe energy storage.

The research team thanks the dedicated company consortium of the project advisory board, as well as the European Research Society for Thin Films e.V. (EFDS) and the IGF funding from the federal government for the opportunity to participate in the competition.

About the project:

Functional coating of battery powders

Europäische Forschungsgesellschaft Dünne Schichten e.V. – EFDS

Project period: 01.04.2022 - 31.03.2024

Funding reference: 01IF22233N

Funding authority: Federal Ministry for Economic Affairs and Climate Action