The future of battery production: innovations and solutions from Schaeffler Special Machinery
In the modern world, electromobility, together with energy transition, is driving unstoppable demand for high-performance battery systems. According to BloombergNEF, around 22 million electric vehicles will be sold worldwide in 2025, an increase of 25% compared to 2024. China in particular dominates the market with a 65% share of all sales, followed by Europe and the USA. This development not only requires groundbreaking innovations in cell technology, but also in the production processes of such complex systems. Schaeffler Special Machinery is at the forefront of this by offering solutions for future-oriented battery production that are modular, automated and sustainable.
Basics of battery systems
A battery system is a multi-layered structure consisting of cells, modules and packs. The cells, often in prismatic, cylindrical or pouch design, are the fundamental units that are combined into modules to eventually be assembled into a battery pack. The chemical basis of most batteries produced today are lithium-ion cells with liquid electrolyte. These offer high energy density and a long service life. In contrast, solid-state batteries, which according to BNEF will be commercialized on a larger scale for the first time in 2025, promise optimized safety and improved performance. They are considered a key technology for the next generation of electric vehicles.
Market development and trends for battery-powered vehicles
Battery production is a highly dynamic and global growth market characterized by constant innovation. New cell technologies, including sodium-ion and solid-state batteries, show great potential for higher energy density and safety - two key factors for widespread application and success in various industries. In parallel, sustainability is becoming increasingly important, requiring the implementation of a circular economy.
These approaches aim to minimize resource consumption and reduce environmental impact by extending and optimizing the life cycle of batteries. BNEF emphasizes that the cost of lithium-ion batteries continues to fall, enabling the production of affordable models. At the same time, the charging infrastructure is being massively expanded - many national fast charging networks have doubled in size in the last 18 months.
Schaeffler Special Machinery: Solutions along the value chain
Schaeffler Special Machinery offers comprehensive solutions tailored to the specific requirements of battery production and thus covers all steps along the value chain.
- Cell preparation: State-of-the-art processes such as laser cleaning, plasma activation and UV coating are used here to create an optimum basis for further processing.
- Module production: Precise cell stacking is followed by robust frame welding and special contacting by laser. Sophisticated bonding processes ensure the structural integrity and durability of the modules.
- Pack assembly: In this final production step, the modules are integrated into packs. To guarantee the highest safety standards, comprehensive leak tests and sophisticated high-voltage and functional tests developed by Schaeffler Special Machinery are carried out.
Particularly noteworthy are Schaeffler's pioneering handling concepts, which include tripod robots and direct-driven transfer systems to ensure maximum cycle times and flexible adaptation along the production line.
Technological expertise: gluing, welding, testing
In addition to assembly processes, our experts have extensive knowledge of key manufacturing technologies:
- Adhesive technology: use of 1K and 2K systems with online inspection for the highest quality.
- Laser welding: Precise contacting with OCT monitoring for continuous quality control.
- Testing technology: Modular systems for high-voltage, leak, function and end-of-line tests.
Conclusion: Holistic solutions for battery production
Our global teams at Schaeffler Special Machinery see themselves as pioneering partners for the battery production of the future. With a comprehensive understanding of processes, global infrastructure and a clear focus on innovation and sustainability, we offer complete solutions, from concept development to production readiness. The findings from the BNEF report show that global electromobility is continuing to grow despite political setbacks, particularly in China and Europe.
While the challenges in the US and geopolitical tensions are affecting momentum, technological development - particularly in batteries and charging infrastructure - continues unabated. We are thus demonstrating how battery production can not only be made more efficient and powerful, but also more environmentally friendly - thus making an active contribution to the sustainable mobility of tomorrow.
September 2025
