Nowadays, battery production involves the use of cost‐intensive materials and highly complex production processes. The knowledge of interactions between product properties and process parameters is often limited to best‐practice‐experience rather than based on actual quantitative correlations. This work quantifies the influence of electrode deposition accuracy (process parameter) on the electrochemical performance (product property) of large battery cells (discharge capacity >8 Ah). In total, 40 lithium‐ion battery cells with five different deposition error configurations are manufactured and electrochemically tested. The electrochemical results of these tests show a linear decrease in the discharge capacity with a linear increase in the deposition error. The reduced discharge capacity is attributed to the extended nonoverlap of cathode and anode areas as well as the larger travel distances of intercalating ions.

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Today, lithium-ion batteries are a promising technology in the evolution of electro mobility, but still have potential for improvement in terms of performance, safety and cost. In order to exploit this potential, one promising approach is the replacement of liquid electrolyte with solid-state electrolyte and the use of lithium metal electrode as an anode instead of graphite based anodes. Solid-state electrolytes and the lithium metal anode have favorable electrochemical properties and therefore enable significantly increased energy densities with inherent safety. However, these materials are both, mechanically and chemically sensitive. Therefore, material-adapted processes are essential to ensure quality-assured manufacturing of all-solid-state lithium-ion battery cells. This paper presents the development of a scaled and flexible automated assembly station adapted to the challenging properties of the new all-solid-state battery materials. In the station various handling and gripping techniques are evaluated and qualified for assembly of all-solid-state battery cells. To qualify the techniques, image processing is set up as a quality measurement technology. The paper also discusses the challenges of enclosing the entire assembly station in inert gas atmosphere to avoid side reactions and contamination of the chemically reactive materials.