Solid-State Battery Manufacturing and Production Unique know-how in the industry

Blue Solutions's history and experience in Solid-State Battery Innovation

Blue Solutions brings an unparalleled expertise and leadership in the development, scale-up, production, and recycling of solid-state batteries. Since initiating operations in 2011, the company has forged its reputation as a pioneer in solid-state battery technologies, continually advancing the boundaries of high energy density batteries and redefining industry standards.

BLUE SOLUTIONS’S HISTORY

Key Areas of Solid-State Battery Expertise

In its solid-state battery production process, Blue Solutions has developed state-of-the-art dry cathode manufacturing techniques. This innovative approach improves production efficiency, supports scalability, and reduces environmental impact compared to traditional wet processes with the usage of solvents.

Specializing in lithium metal processing, Blue Solutions ensures the production of high-quality, high-performance battery components. This expertise guarantees structural and chemical integrity, which is crucial for the durability and energy efficiency of the solid-state batteries. Thus Blue Solutions is one of very few companies in the world able to manufacture industrially thin lithium metal foils: 30-60 µm at 50m/s.

The application of proprietary solid polymer electrolytes enhances the safety and operational stability of the batteries. These polymer electrolyte solutions provide superior thermal stability and conductive properties, enabling optimal performance across a wide range of applications and environmental conditions.

Blue Solutions excels at integrating solid-state batteries into end-use applications. The company’s expertise extends to designing sophisticated battery modules and battery packs, complemented by high-level software solutions for pack and multi pack controls (for commercial vehicles), ensuring seamless incorporation into diverse platforms with exceptional operational reliability.

Blue Solutions is leading the way in sustainable energy storage practices. The company’s prototype solid-state battery recycling line has demonstrated the capability to recover up to 90% of lithium metal from used solid-state cells. The ambition of the company is to be able to re-inject this raw material into new solid-state battery manufacturing processes in the near future. This closed-loop approach to resource utilization positions Blue Solutions as a steward of environmentally conscious manufacturing.

Blue Solutions: a unique track record in Solid-State Battery R&D,
production (since 2011) & recycling

454 patents

454 Patents in Blue Solutions’s portfolio, stemming from 20+ years of R&D

3 million cells

3 million SSB cells already installed in shared cars, buses and off-highway vehicles: 600 million km driven

90% recycled

90% recovered lithium metal from used solid-state cells thanks to a first-of-kind prototype line

Production Workflow Overview

This systematic and innovative production process ensures that Blue Solutions stays at the forefront of solid-state battery technology, delivering sustainable, scalable, and high-performance energy storage solutions for various demanding applications.

STEP 1

Cathode & Electrolyte Production
The battery production process begins with the extrusion 
of composite cathode and solid polymer electrolyte materials.

STEP 2

Half-Cell Assembly
The cathode and electrolyte are laminated and prepared for anode integration.

STEP 3

Anode & Half-Cell Integration
Thin lithium metal anodes and 
half-cells are combined into functional units.

STEP 4

Stacking
Films are cut and stacked 
to precision, forming multi-layered cells for solid-state battery packs.

STEP 5

Cell Crimping
Cells are electrically connected 
and sealed in air-tight casings.

STEP 6

Battery Pack Assembly
Modules are assembled into durable packs designed 
for heavy-duty use.

STEP 7

Recycling
Proof of concept work on-going to recover and re-use in new production cycle, showcasing Blue Solutions's commitment to SSB recycling.

Robust Patent Portfolio

Blue Solutions holds an impressive library of 454 patents, a testament to over 20 years of rigorous research and innovation. This intellectual property supports advancements in solid-state battery materials, solid electrolytes, and next-gen battery technologies, solidifying the company’s competitive edge.

DISCOVER OUR TECHNOLOGY AND R&D ROADMAP

Real-World Success

With over 3 million solid-state battery cells deployed in shared cars, buses, and off-highway vehicles, Blue Solutions has undeniably proven the reliability and functionality of its products. These vehicles have collectively traveled more than 600 million kilometers, showcasing the practical viability and performance of solid-state batteries for electric vehicles (EVs) and other demanding applications.

This combination of manufacturing expertise, groundbreaking production capabilities, and a relentless focus on sustainability solidifies Blue Solutions’s position as an industry leader in solid-state battery innovation. The company continues to lay the foundation for a greener, more efficient future in energy storage and electrification.

DISCOVER OUR RECYCLING PROCESS
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