Dürr and GROB have introduced a new concept factory for lithium-ion battery cell production, designed to minimize space and energy use while improving performance and product quality. Key technologies include dry electrode coating, which eliminates the need for a drying process, and advanced Z-folder technology for high-speed cell assembly with integrated notching.
The two companies have cooperated since 2022 to provide system solutions for lithium-ion battery manufacturing in Europe and North America. According to German Wankmiller, CEO of the GROB Group, “With our expanded portfolio of highly available machines and systems, we jointly cover almost the entire value chain for battery cell production with our own technologies.”
The Dürr and GROB concept factory for lithium-ion battery cell production requires 50 percent less space and 70 percent less energy, resulting in significantly higher space efficiency and lower operating costs.
The new concept factory uses Dürr’s X.Cellify DC dry coating platform, implementing the Activated Dry Electrode® process from U.S.-based LiCAP Technologies. Unlike conventional slurry-based wet coating, this approach applies dry-mixed active materials and eliminates solvent drying and recovery, saving up to 70 percent energy and 50 percent floor space. The process also allows excess film material to be fully recycled, reducing waste and improving material efficiency.
The partners’ proof-of-concept facility in Chassieu, France, operated by Dürr subsidiary Ingecal, specializes in calender technology for precision electrode processing. Here, free-standing electrode films are produced and laminated onto collector foils in a closed-loop process that minimizes scrap while ensuring consistent layer density and porosity.
GROB’s latest Z-folder integrates the notching process to increase throughput and achieve 95 percent system availability. Dürr has also introduced a high-pressure electrolyte filling process, capable of operating at up to 30 bar, enabling faster and more precise electrolyte distribution and improved penetration into the active material.
Further innovations include Dynamic Gap Control for precise calendering, laser-based drying for greater efficiency, and digitalized process integration through simulation and iTAC MES/MOM software. Together, these technologies provide real-time quality analysis and traceability for improved yield and sustainability across production lines.
Dürr has also optimized its wet-coating platforms with automated slot-die control and enhanced calendering precision. “Adding automated slot-die profile control provides our customers with the ability to not only reduce machine startup time, but also to ensure quality throughout the production process by maintaining coating uniformity,” explained Adam Shambeau, Senior Director of Dürr Lithium-Ion Batteries Americas. “Scrap reduction and machine uptime are critical to our customers’ success, so enhancing our products through automation or innovating our offerings with dual-side coating technology to reduce the total cost of ownership are two great examples where our products bring value to our customers.”
About Dürr Group
Headquartered in Bietigheim-Bissingen, Germany, Dürr Group is a global mechanical and plant engineering company specializing in production technologies, automation, and digital manufacturing systems. Its portfolio spans automotive, industrial, and energy applications, including coating systems, final assembly technology, and environmental process equipment. For more information, please click here.
About GROB Group
Founded in 1926 and headquartered in Mindelheim, Germany, GROB Group develops production and automation systems for the automotive, aerospace, and electromobility industries. The company manufactures equipment for electric motors, batteries, and fuel cells, operating in more than 15 locations worldwide. To learn more, please click here,
Source/Photo Credit: Durr Group
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Molly is the Founder, Publisher, and Editor-in-Chief of Components Source Network, the industry’s first and only known 100% woman- and disability-owned and led B2B publishing platform serving the global high-tech manufacturing and engineering sectors. Her portfolio includes EV + Battery Tech Monthly and ten additional specialized e-news sites. With more than 25 years of experience spanning strategic technical marketing, public relations, and business development in highly specialized technical markets, she also leads Embassy Global, LLC, a virtual consultancy that has supported the growth of more than 200 high-tech industry brands worldwide since 2008. In addition to her publishing and advisory work, Molly has been appointed to serve as Second Vice Chair of the Government Team for the Women’s Business Enterprise National Council (WBENC) Forum, beginning in 2026, supporting policy development and advocacy initiatives advancing women-owned businesses. A long-standing voice for small business, supplier diversity, and women in STEM, she was also a 2025 finalist for the WBEC Metro New York Outstanding Advocate Award. Connect with her on LinkedIn.
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