New requirements for quality and in-process controls of next-generation batteries

This industrial thesis, carried out at MG SpA (Marposs Group) and Marposs SpA, investigates the critical challenges that next-generation battery chemistries face during the scale-up process from laboratory research to industrial production. The primary objective is to support the development and adaptation of advanced process-control and quality-testing instrumentation, facilitating reliable and efficient technology transfer from R&D to manufacturing lines. The transition toward electric mobility, driven by the global fight against climate change, is accelerating the development of advanced battery technologies. As the transportation sector progressively shifts from internal combustion engines to electrified systems, demand for high-performance batteries continues to grow. This expansion is pushing industrial players to explore innovative cell chemistries capable of meeting stringent automotive requirements while reducing Europe’s dependence on the currently dominant Asian battery market. The work begins with an overview of the European battery market and the fundamentals of electrochemical cell operation, highlighting both state-of-the-art lithium-based systems and emerging solid-state technologies. A detailed market analysis is then conducted to assess business opportunities and guide strategic R&D investments. Particular attention is devoted to leak testing methodologies, which are essential for ensuring manufacturing robustness, product safety, and long-term reliability. The thesis presents and validates several leak detection approaches, including the theoretical and experimental optimization of the helium bombing test through a custom-designed master leak model, and an electrolyte-tracing method applied to sealed pouch cells. Additionally, the reactivity of sulphide-based solid-state electrolytes under controlled humidity conditions is investigated, given their sensitivity to moisture and potential hydrogen sulphide generation. Finally, the thesis introduces the development of an innovative dilatometry system (M-EET) for operando monitoring of electrode thickness variations under mechanical load, enabling advanced chemo-mechanical characterization. Overall, the research provides experimental insights and methodological tools to help anticipate future industrial needs in next-generation battery manufacturing.