This review draws on a systematic literature review and bibliometric analysis to examine how Digital Twins (DTs), Extended Reality (XR), and Artificial Intelligence (AI) support the reconfiguration of Cyber–Physical Systems (CPSs) in modern manufacturing. The review aims to provide an updated overview of these technologies’ roles in CPS reconfiguration, summarize best practices, and suggest future research directions. In a two-phase process, we first analyzed related work to assess the current state of assisted manufacturing reconfiguration and identify gaps in existing reviews. Based on these insights, an adapted PRISMA methodology was applied to screen 165 articles from the Scopus and Web of Science databases, focusing on those published between 2019 and 2025 addressing DT, XR, and AI integration in Reconfigurable Manufacturing Systems (RMSs). After applying the exclusion criteria, 38 articles were selected for final analysis. The findings highlight the individual and combined impact of DTs, XR, and AI on reconfiguration processes. DTs notably reduce reconfiguration time and improve system availability, AI enhances decision-making, and XR improves human–machine interactions. Despite these advancements, a research gap exists regarding the combined application of these technologies, indicating potential areas for future exploration. The reviewed studies recognized limitations, especially due to diverse study designs and methodologies that may introduce risks of bias, yet the review offers insight into the current DT, XR, and AI landscape in RMS and suggests areas for future research.

Battery cell production is a complex process chain with interlinked manufacturing processes. Calendering in particular has an enormous influence on the subsequent manufacturing steps and final cell performance. However, the effects on the mechanical properties of the electrode, in particular, have been insufficiently investigated. For this reason, the impact of different densification rates during calendering on the electrochemical cell performance of NMC811 (LiNi_0.8Mn_0.1Co_0.1O₂) half-cells are investigated to identify the relevant calendering parameters. Based on this investigation, an experimental design has been derived. Electrode elongations after calendering in and orthogonal to the running direction of the NMC811 cathode are investigated in comparison with a hard carbon anode after calendering. Elongations orthogonal to the machine direction are observed to have no major dependencies on the compaction rate during calendering. In the machine direction, however, significant elongation occurs as a dependency of the compaction rate for both the hard carbon anode and the NMC811. In addition, the geometric shape of the NMC811 electrodes after separation into individual sheets is investigated with regard to different compaction rates during calendering. It is shown that the corrugations that occur during calendering are propagated into the single electrode, depending on the compaction rate.

Sodium‐ion batteries are an emerging technology that is still at an early stage of development. The electrode processing for anode and cathode is expected to be similar to lithium‐ion batteries (drop‐in technology), yet a detailed comparison is not published. There are ongoing questions about the influence of the active materials on processing parameters such as slurry viscosity, coating thicknesses, drying times, and behavior during fast drying. Herein, the expected drying time for the same areal capacity of anodes (graphite vs. hard carbon) and cathodes (lithium iron phosphate vs. Prussian blue analogs) are compared based on respective specific capacities reported in the literature. Estimates are made for the materials’ impact on production speed or dryer length. Within the experimental part, water‐based slurries of the same composition are mixed using different active materials according to identical procedure and the viscosity is compared. When drying at a constant drying rate (0.75 g m⁻² s⁻¹), lithium iron phosphate electrodes with different areal capacities (1–3 mAh cm⁻²) are shown to have the highest adhesion. For high drying rates (3 g m⁻² s⁻¹) at constant areal capacity, especially the investigated electrodes based on hard carbon show that no binder migration occurs.