The Fraunhofer Institute for Industrial Mathematics (ITWM) has developed new technological solutions to analyse battery behaviour during charging and discharging, as well as cell production and ageing. The results will be presented at the Battery Show Europe 2025.
One of the main developments is the BEST simulation software, which enables detailed 3D analysis of electrode microstructure, a key component of battery cells.
This allows researchers to predict behaviour during charge-discharge cycles, optimise performance and improve system efficiency, according to Jochen Zausch, Head of the Electrochemistry and Batteries team.
In parallel, the institute is working on cell ageing models. Capacity loss, increased internal resistance, and mechanical stress are some of the factors under study. The aim is to mitigate these effects to reduce resource use in production, stated Falco Schneider, battery ageing specialist.
In addition, the DiBaZ project — funded by the regional government — seeks to digitalise cell manufacturing by creating a digital twin for the product’s entire lifecycle. This includes simulation of processes such as electrode calendaring, electrolyte wetting, and foam encapsulation. For this, Fraunhofer ITWM uses tools such as FeelMath, FLUID and FOAM.
According to project coordinator Konrad Steiner, these solutions also enable non-destructive quality control and predictive energy management throughout production.
In this context, the institute has also advanced the use of terahertz measurement technology to inspect electrode coatings. This optical method is contactless, non-destructive and completely safe for health.
Joachim Jonuscheit, Deputy Head of the Department for Material Characterisation and Testing, highlighted the industrial potential of this technique.
During the event in Stuttgart, the institute will showcase these technologies at the Fraunhofer Battery Alliance joint stand (Hall 10, Stand J40), including its inline layer thickness measurement tool and the latest updates to the BEST simulation software.
