Recycling plays a crucial role in achieving a sustainable production chain for lithium-ion batteries (LIBs), as it reduces the demand for primary mineral resources and mitigates environmental pollution caused by improper disposal. Disassembly of the LIBs is typically the preliminary step preceding chemical recovery operations, facilitating early separation of components consisting of different materials. Despite that extensive research has been conducted on the chemical processes involved in the recycling of LIBs, systematic studies on disassembly processes in the recycling process are relatively scarce. In this research, a systematic review was conducted on the publications from major databases, such as Scopus, SpringerLink, and others, to explore the current state of disassembly processes in LIBs’ recycling. The results emphasize disassembly as a crucial process for achieving a high material separation rate and ensuring a high degree of purity of the recycled active material. Moreover, automated disassembly can significantly raise productivity and reduce disassembly costs. Thus, it improves disassembly efficiency and increases economic as well as environmental benefits. Most researchers have focused on disassembly at the pack or module level. Investigation into extending the disassembly depth from cell to individual components is limited, particularly in automated approaches. Therefore, further research is highly recommended to explore the feasibility and potential of novel automated disassembly procedures at the cell level. This can contribute to improving the efficiency and sustainability of the recycling process for LIBs.

Lithium‐ion battery (LIB) manufacturing requires a pilot stage that optimizes its characteristics. However, this process is costly and time‐consuming. One way to overcome this is to use a set of computational models that act as a digital twin of the pilot line, exchanging information in real‐time that can be compared with measurements to correct parameters. Here we discuss the parameters involved in each step of LIB manufacturing, show available computational modeling approaches, and discuss details about practical implementation in terms of software. Then, we analyze these parameters regarding their criticality for modeling set‐up and validation, measurement accuracy, and rapidity. Presenting this in an understandable format allows identifying missing aspects, remaining challenges, and opportunities for the emergence of pilot lines integrating digital twins. Finally, we present the challenges of managing the data produced by these models. As a snapshot of the state‐of‐the‐art, this work is an initial step towards digitalizing battery manufacturing pilot lines, paving the way toward autonomous optimization.

Electrolyte filling and wetting is a quality-critical and cost-intensive process step of battery cell production. Due to the importance of this process, a steadily increasing number of publications is emerging for its different influences and factors. We conducted a systematic literature review to identify common parameters that influence wetting behavior in experimental settings, specifically focusing on material, processes, and experimental measurement methods but excluding simulation studies. We reduced the initially found 544 records systematically to 39 fully labeled articles. Our profound analysis guided by attributed labelings revealed current research gaps such as the lack of a holistic view on measurement methods for filling and wetting, underrepresented studies relevant to series production, as well as the negligence of research targeting the transferability of results from the material to the cell level, while also examining the measured variables’ interactions. After comparatively illustrating and discussing implications of our findings, we also discussed limitations of our contribution and suggested ideas for potential further research topics.

Demand for lithium-ion battery cells (LIB) for electromobility has risen sharply in recent years. In order to continue to serve this growing market, large-scale production capacities require further expansion and the overall effectiveness of processes must be increased. Effectiveness can be significantly optimized through innovative manufacturing technology and by identifying scrap early in the production chain. To enable these two approaches, it is imperative to quantify safety- and function-critical product features in critical manufacturing steps through appropriate measurement techniques. The overview in this paper on quality control in LIB production illustrates the necessity for improved inspection techniques with X-rays to realize a fast, online measurement of inner features in large-scale cell assembly with short cycle times and to visualize inner product-process interactions for the optimization in electrolyte filling. Therefore, two new inspection techniques are presented that contribute to overcoming the aforementioned challenges through the targeted use of X-rays. First, based on the results of previous experiments in which the X-ray beam directions were deliberately varied, a online coordinate measurement of anode-cathode (AC) overhang was developed using a line detector. Second, a new concept and the results of a continuous 2D visualization of the electrolyte filling process are presented, which can be used in the future to optimize this time-critical process step. By using a X-ray-permeable and portable vacuum chamber it is possible to quantify the influence of process parameters on the distribution of the electrolyte in the LIB.

In lithium-ion battery manufacturing, wetting of active materials is a time-critical process. Consequently, the impact of possible process chain extensions such as lamination needs to be explored to potentially improve the efficiency of the electrode and separator stacking process in battery cell manufacturing. This paper addresses the research gap of the unexplored effects of lamination on the wetting rate of electrode-separator assemblies in pouch cells. Based on the triangulation of three measurement techniques (gravimetric, optical, electrochemical), a correlation between lamination and wettability of electrode-separator assemblies is experimentally demonstrated, thus providing an important research contribution.

The production of lithium‐ion batteries (LIBs) is crucial for advancing energy‐storage technologies, yet uncertainties remain regarding key influencing factors along the process chain. Specifically, the electrolyte filling process is critical for optimal cell performance. In this study, the unknown effects of differential pressure, different temperature for the materials, and the geometrical cell design are investigated through the aspect ratio (lengths to height ratio) on the wetting behavior of LIB cells. Using a custom‐designed test stand, impedance change |ż| at 1 Hz is measured during electrolyte dispensing and wetting while varying temperature, pressure, and the cells’ aspect ratio. In the results, it is indicated that lower evacuation pressures significantly increase the wetting rate, reducing wetting durations. Higher differential pressures enhance wetting efficiency by compressing the electrode‐separator composite (ESC) materials. Elevated electrolyte temperatures decrease viscosity, resulting in faster wetting times. Temperature variations between the ESC material and electrolyte lead to heat equalization, with no discernible impact on partial gas pressure. Additionally, increased aspect ratios in cell design reduce wetting times due to shorter distances for the wetting front to travel. In these findings, valuable insights are provided for optimizing battery cell manufacturing, contributing to improved efficiency and performance in next‐generation battery technologies.