Publication date: 15th December 2025
Scaling up solid-state batteries (SSBs) from controlled lab-scale demonstrations to commercially relevant pouch cells remains a major barrier to their widespread adoption, especially when inorganic solid electrolytes are used. [1,2] Although solid-state batteries offer substantial advantages, including enhanced safety, higher energy density, and compatibility with lithium-metal or silicon-rich anodes, the transition from well-controlled laboratory cells to larger, application-relevant formats introduces a series of complex processing challenges. These challenges include controlling large-batch electrolyte synthesis, ensuring consistent particle properties, and enabling scalable composite electrode fabrication. At the cell level, achieving sufficient densification demands high uniaxial or isostatic pressure, but applying these pressures uniformly in larger formats increases the risk of mechanical stress, cracking of brittle sulfide materials, and interfacial contact loss. As cell size grows, maintaining homogeneous stack pressure and stable, low-resistance interfaces becomes increasingly difficult, and even minor voids or micro-cracks can raise impedance, hinder ionic transport, and reduce cycling stability, ultimately limiting manufacturability and performance. [3]
In this talk, I will present our recent progress in developing solid-state pouch cells based on the argyrodite-type electrolyte Li₆PS₅Cl, combined with LiNi₀.₈Mn₀.₁Co₀.₁O₂ and advanced silicon-based composite anodes. I will highlight how key processing parameters, such as particle size distribution, compaction and formation pressure, and interfacial engineering, affect the microstructural stability, ionic transport, and electrochemical performance of both individual components [4] and the complete pouch cell.
D.R. acknowledge financial support by Austrian Federal Ministry for Digital and Economic Affairs, the National Foundation for Research, Technology and Development and the Christian Doppler Research Association (Christian Doppler Laboratory for Solid-State Batteries) and by the Research Council of Norway through Project no. 336417.
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