Battery Technologies | HSSMI

BATTERY TECHNOLOGIES CIRCULAR ECONOMY DIGITAL MANUFACTURING HYDROGEN SYSTEMS MANUFACTURING STRATEGY LEAN MANUFACTURING & AUTOMATION ELECTRIC DRIVES MANUFACTURING ENGINEERING SUPPLY CHAIN & LOGISTICS

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BATTERY TECHNOLOGIES

Our battery technologies team covers everything from concept development to facility launch, from pilot scale to high volume manufacture and scale up, as well as processes optimisation, and manufacturing strategy. We know the who, what, how and how much, and pride ourselves on working with some of the UK’s leading cell and pack manufacturers. We can also assist you in navigating the complex field of battery-related legislation and develop strategies for battery end-of-life recovery.

BATTERY TECHNOLOGIES KEY SERVICES

Gigafactory Planning & Design

Cathode Active Material (CAM) Manufacture Definition

Battery – End of Life Strategy Development

Pack Manufacturing Process and Facilitation Definition

BATTERY TECHNOLOGIES KEY PROJECTS

GIGAFACTORY | Past Project

This project focused on assessing the commercial feasibility of establishing a scalable battery cell manufacturing facility in the UK, with the capability to ramp up to a Gigawatt hour worth of cell production. The project resulted in a business case and manufacturing blueprint for the proposed Gigafactory that advanced production and supply chain readiness.

AcouBat | Past Project

AcouBat will test a novel acoustic battery testing method in a practical setting – on AMTE Power’s cell manufacturing line. Alongside the physical validation, a digital simulation of the testing facility will be created by HSSMI to determine where on the production line the acoustic testing method could bring the most benefit.

THURSO+ | Past Project

In Thurso+, HSSMI is working together with AMTE Power to explore ways of increasing the productivity of AMTE Power’s existing cell manufacturing facility and develop a plan to transition to a high-volume plant. The project will explore how AMTE Power’s facility could best adopt the innovative methodologies, procedures and equipment used in state-of-the-art Gigafactories outside of the UK.

Li-BAR | Past Project

Li-BAR is a six-month study to determine the feasibility of establishing co-located battery pack assembly and remanufacturing facilities. Co-locating the sites will provide opportunities to optimally use batteries throughout their lives, maximise value leveraged from components through reuse, minimise operational and capital costs, and reduce waste.

H1PERCHAIN | Recent Project

The H1perChain (high performance EV supply chain) project addresses the need for a step change reduction in battery pack costs by developing the UK component and sub-system supply chain capabilities, establishing robust and high-speed laser welding processes, and providing innovative design and manufacturing solutions for higher volume battery packs.

VALUABLE | Past Project

Project VALUABLE’s key objectives were to develop commercially viable metrology and test processes as well as new supply chain concepts for recycling, reuse and remanufacturing of automotive lithium-ion batteries to create a complete End-of-Life (EoL) supply chain network within the UK.

CICERO | Past Project

The concept behind CICERO was straight-forward – tear down batteries that are at the end of first life to a modular level and re-structure them for use in a classic vehicle. HSSMI, with inputs from other partners, created flexible battery disassembly and re-assembly processes, enabling both stations to be re-configured to perform either function as necessary.

HyFES | Past Project

The Hybrid Fusion Energy System (HyFes) project was an initiative to fit marine vessels with batteries and allow them to operate along the River Thames in a similar way a hybrid car would. The MBNA Thames Clipper river boat service and their high-speed catamarans were chosen as a test bed, due to its stop start capabilities in operation that would suit itself to hybrid propulsion.

BATTERY TECHNOLOGIES CASE STUDIES

Simulating Acoustic Battery Testing
for High-Volume Battery Production

In the AcouBat project, HSSMI has been working together with JW Froehlich and UCL to develop a simulation to integrate the acoustic battery testing method, developed by UCL, onto AMTE Power’s production line and, more generally, to address AMTE Power’s productivity and upscaling ambitions.

Building Towards a Co-Located Battery Assembly and Remanufacture Facility with Ultramax

The study, carried out by HSSMI and Ultramax, enabled the latter to assess the associated costs and facility requirements for multiple product and production mix scenarios. This played a significant role in developing a scale up strategy and business case for future production.

A Strategy to Scale Up Towards a Gigafactory with AMTE Power

AMTE teamed up with HSSMI to optimise its manufacturing model. Drawing on lean manufacturing principles, HSSMI assessed AMTE’s current capacity, pinpointed higher impact opportunities to unlock volume production at Thurso, and worked to prototype how this modelling can support even higher volume at Gigafactory production rates.

BATTERY TECHNOLOGIES INSIGHTS

Feasibility Study: The UK’s First Near-Closed Loop Battery Pack Production Facility

HSSMI has joined Ultramax in a six-month study called Li-BAR to determine the feasibility of establishing co-located battery pack assembly and remanufacturing facilities. It is anticipated that co-locating the sites will provide opportunities to optimally use batteries throughout their lives.

Discussions with the Industry: Non-Destructive Methods for Battery Testing to Identify Failure Modes Where They Happen

The development of non-destructive inline testing machines and procedures will enable manufacturers to employ a no-faults-forward principle, thereby reducing costs invested in failed parts, limiting unnecessary waste and optimising the number of FA&T (formation, ageing and testing) channels.

Why Does the UK Need a Lithium Supply Chain?

In order to meet future manufacturing demand, a domestic supply of lithium will need to be carefully balanced through mining and a well-established battery recycling industry. The CLiCCC project aims to support the UK in establishing a secure supply of lithium for various industrial applications.

Optimise Existing Manufacturing Assets Instead of Channelling Additional Investment, Thurso+ Project Concludes

HSSMI and AMTE Power embarked on Thurso+ to establish a pathway for AMTE Power to upscale its battery cell manufacturing capability in Thurso. However, the lessons learned from the project will help boost the UK’s cell manufacturing capability overall.

Exploring Pathways and Opportunities for EV Battery Reuse

This whitepaper explores how an EV battery reinstaller can approach EV battery teardown and reuse at scale. It covers the entire end-of-life journey of an EV battery, the legislation surrounding an EoL battery’s classification as waste, as well as implications to transportation.

Discussions with the Industry: Estimating the Economic and Environmental Benefits of Battery Recovery Methods

To understand the impact battery design has on the costs associated with different battery recovery methods and their economic feasibility, HSSMI developed a battery lifecycle cost estimation methodology as part of the VALUABLE project.

The UK Must Accelerate Battery Cell Production to Meet Rapidly Increasing Demands from the Automotive Sector

Further investment is necessary into the UK battery cell industry to not only meet the automotive sector’s needs but to secure the future of the UK industry which may be shut out as global supply is bought up.

Urgent Build of More Gigafactories Crucial to Securing the Future of UK Car Production

By 2040, there will be a need for 140 GWh in battery cell capacity, equivalent to five Gigafactories. Currently however, there is only 3 GWh of production in the UK and, by 2030, just a further 45 GWh planned, leaving a major gap – over 95 GWh – between the forecasted supply and demand.

Discussions with the Industry: Reconciling Design for Manufacture and Design for End of Life

Implementing DfEoL principles into battery assembly, and keeping in mind the potential to disassemble a product and recover materials and value at its end of life, could present an attractive opportunity to OEMs if the control of the battery and its remaining value were to be retained with the OEM.

Discussions with the Industry: Barriers Facing the Recycling Industry, from Infrastructure to Testing and Accreditation

Recycling businesses are keen to take up automotive traction battery recycling, but there are several technical and economic challenges that deter investment, including competitive export markets, lack and difficulty of obtaining data, a skills gap, and limited experience.

Discussions with the Industry: Defining Battery Second Life Opportunities and Exploring Legislative Improvements

Project VALUABLE, led by HSSMI, has been instrumental in shedding light on second life opportunities for li-ion batteries. As the project closed at the end of March, we are now sharing our findings in order to generate discussion amongst the public and inspire further research.

Retrofitting Classic Cars with Second-Life EV Batteries

A new feasibility study called CICERO will examine how EV batteries at the end of their first life could be given a second life in classic or heritage vehicles. A digital twin of the process will enable battery testing to meet end user requirements for range or power.

Update from Thurso+: Optimising Existing Equipment to Move Towards a High-Volume Cell Manufacturing Plant

Through a thorough analysis of the current plant, HSSMI’s work has revealed that significant cell volumes could be produced by optimising existing equipment, and by utilising increased shift patterns, without significant capital investment.

Using Acoustic Testing to Improve and Accelerate Battery Production

HSSMI has teamed up with AMTE Power, University College London, and JW Froehlich, in the new AcouBat project, which will use novel, acoustic battery testing processes to improve battery production.

The Next Steps Towards Increasing UK Battery Cell Manufacturing Capability with AMTE Power

HSSMI is continuing its partnership with AMTE Power and exploring opportunities to enhance the UK’s battery cell manufacturing capability. Over the next five months, HSSMI will undertake a feasibility study to explore ways of increasing the productivity of AMTE Power’s existing facility.

Explore the Ways of Recovering and Maximising Battery Value in Our Latest Report

Electric vehicle lithium-ion batteries retire from transport applications when they reach 70-80% capacity, presenting an opportunity for OEMs to cascade this value into new functions and eventually recovering the valuable materials these batteries are made from.

A Look at the Global Battery Alliance Report “A Vision for a Sustainable Battery Value Chain in 2030” with HSSMI Experts Alberto Minguela and Robin Foster

In light of the recently published GBA report “A Vision for a Sustainable Battery Value Chain in 2030”, I sat down with HSSMI experts to discuss their thoughts on the report, the current state of batteries in the UK and where we can go from here.

Introducing HSSMI’s New Battery Lifecycle Value Estimation Service

HSSMI has launched a digitally-enabled service designed to support businesses understand what value can be recovered from a specific battery design once this is no longer of use for automotive applications.

The HyFes Project | Hybrid Fusion Energy System

Controlling the switch between engine and battery power sits the HyFes algorithm. This takes input from a suite of onboard sensors and using machine learning is able to determine the best course of action to power the boat.

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