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New Research Approaches for Ultralight Lithium-Sulfur Batteries
Lithium-sulfur batteries represent a promising alternative
to conventional lithium-ion systems. To overcome existing technological
hurdles of this cell chemistry, the Fraunhofer Institute for Material and Beam
Technology IWS and its partners are investigating a new cell architecture that
reduces electrolyte content and adapts solid-state chemistry. Their goal is to
develop practical cell concepts that combine high energy density with improved
cycle life and enhanced safety. Two research projects – AnSiLiS, funded by the
German Federal Ministry of Research, Technology and Space (BMFTR), and
TALISSMAN, funded by the EU’s Horizon Europe program – form the structural
framework for this work. The project aims to develop a solid-state lithiumsulfur
cell that provides comparable energy while weighing significantly less
than current batteries.
Conventional lithium-sulfur cells exhibit limited cycle life because their liquid
electrolytes promote the formation of soluble polysulfides. These byproducts result in
material losses and accelerated cycle stability degradation. Fraunhofer IWS researchers
are pursuing an alternative approach: the direct conversion of sulfur to solid lithium
sulfide in a predominantly solid-state environment, entirely free of liquid electrolyte.
Initial lab results suggest that in the future this architecture can technically achieve a
specific energy of more than 600 watt-hours per kilogram with stable cycling behavior.
AnSiLiS: Materials Development, Simulation, and Cell Integration
The AnSiLiS project focuses on developing a sulfur-carbon composite cathode. This will
be examined in combination with a thin lithium-metal anode and a hybrid electrolyte
system in minimal quantity. TU Dresden and the University of Jena explore the
electrochemical interactions between the electrolyte and active materials. Helmholtz-
Zentrum Berlin contributes expertise in operando analytics and 3D tomography.
Molecular dynamics simulations support the cell development process, enabling precise
evaluations of component stability and compatibility on different scales.
TALISSMAN: Scaling and Industrial Validation
The EU project TALISSMAN adds industrial scaling and application validation to the
research. Coordinated by the Basque institute CIDETEC, nine partners from Spain,
France, Italy, and Germany are developing two cell generations for electric mobility
applications. Their targets include energy densities of up to 550 watt-hours per
kilogram, the integration of non-flammable quasi-solid electrolytes, and production
costs of under 75 euros per kilowatt-hour. The cell design will remain compatible with
existing lithium-ion battery production lines.
TALISSMAN: Scaling and Industrial Validation
The EU project TALISSMAN adds industrial scaling and application validation to the
research. Coordinated by the Basque institute CIDETEC, nine partners from Spain,
France, Italy, and Germany are developing two cell generations for electric mobility
applications. Their targets include energy densities of up to 550 watt-hours per
kilogram, the integration of non-flammable quasi-solid electrolytes, and production
costs of under 75 euros per kilowatt-hour. The cell design will remain compatible with
existing lithium-ion battery production lines.
All production steps take place at the institute’s Advanced Battery Technology Center
(ABTC) in Dresden. This facility features a flexible line for electrode manufacturing,
utilizing classic slurry coating or DRYtraec, as well as laser cutting in dry air, multilayer
stacking, thermal sealing, and formation, with the option for cyclic aging. Combined
with analytics and process simulation, this setup enables end-to-end cell development
from a single source of origin. Fraunhofer IWS delivers more than lab-scale results – it
provides near-application demonstrators. All cells undergo comprehensive
electrochemical characterization. Industry partners from aerospace, drone technology,
and electromobility benefit from reduced development risk, accelerated technology
transfer, and economically viable battery production. Energy densities above 600 watthours
per kilogram and specific costs below 75 euros per kilowatt-hour are within
reach.
Target Applications
Aviation, unmanned aerial systems, and portable energy storage systems demand
excellent energy-to-weight ratios. The cell concepts under development in AnSiLiS and
TALISSMAN directly address these requirements. The combination of optimized
materials, in-depth analysis, and process-driven development will pave the way for
lithium-sulfur batteries in applications where conventional technologies reach their limits. Functional prototypes are expected to validate the projected performance in the
coming years.
Dr. rer. nat. Holger Althues
Fraunhofer Institute for Material and Beam Technology IWS Dresden
Phone +49 351 83391-3476
Winterbergstraße 28
DE-01277 Dresden
www.iws.fraunhofer.de
holger.althues@iws.fraunhofer.de
https://www.iws.fraunhofer.de/en/newsandmedia/press_releases/2025/press-release_...
Battery of the Future: Fraunhofer IWS develops new lithium–sulfur cell concepts with reduced electro ...
Source: Martin Förster
Copyright: © Martin Förster/Fraunhofer IWS
Fraunhofer IWS develops high-energy lithium-sulfur cells with solid electrolytes and a scalable cell ...
Copyright: © Fraunhofer IWS/generated by AI
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Battery of the Future: Fraunhofer IWS develops new lithium–sulfur cell concepts with reduced electro ...
Source: Martin Förster
Copyright: © Martin Förster/Fraunhofer IWS
Fraunhofer IWS develops high-energy lithium-sulfur cells with solid electrolytes and a scalable cell ...
Copyright: © Fraunhofer IWS/generated by AI
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