FREDY

Motivation 

The transformation towards climate-neutral mobility and resilient energy systems requires sustainable and cost-efficient battery production. Conventional slurry-based electrode manufacturing is energy-intensive and dependent on critical solvents. Dry battery electrode (DBE) coating offers significant energy and cost savings, but current processes rely on PTFE binders and PFAS-based materials that face increasing regulatory restrictions.At the same time, next-generation lithium-ion and solid-state batteries demand enhanced interface stability and material compatibility.

The FREDY project addresses these technological and ecological challenges by advancing fluorine-free binder systems and enabling solvent-free, scalable dry coating technologies. In doing so, the project strengthens technological sovereignty in Europe and Taiwan and reduces dependencies within global battery supply chains.

Objectives and Approach

FREDY combines the complementary expertise of Fraunhofer IWS and Industrial Technology Research Institute (ITRI, Taiwan) to future-proof dry electrode manufacturing. Fraunhofer IWS focuses on the development of materials, processes and equipment for solvent-free production of battery electrodes using fluorine-free binders.

Core activities include the development of dry coating processes for lithium-ion and solid-state batteries, process parameter optimization, and validation in prototype cells. ITRI contributes advanced particle surface modification, thin-film technologies such as ALD and sputtering, and intelligent machinery development. Together, the partners adapt material formulations, engineer stable interfaces, and design scalable roll-to-roll process concepts up to TRL 5, including extruder and calender innovations.

Innovation and Perspectives

FREDY pioneers the integration of fluorine-free binder chemistry with advanced surface functionalization and scalable dry coating equipment. By replacing PFAS-based binders and tailoring active material interfaces, the project expands the operational window of dry processing while improving electrochemical stability. The combined material-process-equipment approach enables robust, energy-efficient manufacturing routes for both lithium-ion and solid-state battery technologies. Demonstrator cells validate industrial relevance and create a pathway toward commercialization. The outcomes secure the long-term viability of solvent-free electrode production, enhance sustainability, and position the partners as leading innovators in next-generation battery manufacturing technologies.