FAST - Formation and Aging for Sustainable Battery Technologies

FAST targets a bottleneck in lithium-ion battery manufacturing: the time-, energy- and cost-intensive nature of the formation, ageing and testing processes. These steps, which take place at the end of the cell manufacturing process, are essential for solid-electrolyte interphase (SEI) and cathode-electrolyte interphase (CEI) formation. The properties of these layers, such as their ionic conductivity and electronic insulation, directly influence battery performance characteristics such as cycle life, capacity and safety. However, the scientific and mechanistic details of the formation processes are poorly understood and their development to date has mostly relied on empirical optimisation. Improving these steps is a high impact target for industrial innovation and commercial viability.

FAST aims to develop a science-based, scalable and more sustainable formation, ageing and testing framework, optimised initially for high nickel NMC (LiNi_0.9Mn_0.05Co_0.05O₂ and above) paired with graphite or graphite–silicon anodes.

The project will manufacture single- and multi-layer pouch cells and develop novel formation protocols, optimising external stimuli to reduce energy and cost. Sensored cells will track, in real-time, the physical and chemical changes that occur during formation and ageing, providing direct insight into SEI/CEI dynamics. Characterisation tools will reveal interface evolution under realistic formation conditions, providing previously unmeasured mechanistic data to inform and validate new protocols.

Researchers will also rapidly screen electrolyte formulations for wetting behaviour, gassing, and interfacial stability, using novel methods on active material powders including pre-lithiated materials. The effects of both passive formation techniques (the use of pressure, temperature and rest periods), and active formation (using electric or magnetic gradients and pulsed currents) will be investigated. The desirability of the processes will be assessed by comparing energy input, time, capacity and energy losses during formation and cycling, with the cycle life of the resultant cells. These will be benchmarked against industrial standards and validated in full-format cells at the UK Battery Industrialisation Centre.

Timeline with milestones / deliverables (to September 2028)

• Validated formation protocols that reduce time, energy consumption, maximise energy and cycle-life, and improve reproducibility.
• Novel formation and ageing protocols using variable temperature, pressure, magnetic and field-assisted approaches.
• Mechanistic understanding of SEI/CEI formation as a function of electrolyte, protocol, and materials chemistry.
• Sensored cell platforms for real-time diagnostics and quality assurance.
• Data-driven battery models that integrate electrochemical, physical, and spectroscopic datasets to enable predictive control over formation.

Project innovations

FAST will generate novel design rules for interphase control, electrolyte formulation, and formation process optimisation. Measures of success will include reduced cell processing times, improved cell yield and longevity, and faster deployment of advanced chemistries. Through links to UKBIC and industrial partners, FAST will enable rapid translation of findings to manufacturing environments.

FAST aims to bridge the gap between laboratory research and industrial application, and to establish the UK as a leader in intelligent, sustainable cell finishing processes, providing a foundation for the next generation of lithium ion and future battery chemistry production.

Duration
1 October 2025 – 30 September 2028

Project funding
£6 million

Principal Investigators
Professor Emma Kendrick
University of Birmingham

Project Leader
Dr Dominic Spencer-Jolly
University of Birmingham

University Partners
University of Birmingham (Lead)
University of Cambridge
University of Nottingham
University of Oxford
University of Warwick

Research Organisations, Facilities and Institutes
UK Battery Industrialisation Centre

+ 4 Industrial Partners