The STELLAR project aims to industrialise next-generation lithium-metal (LiM) anodes for solid-state and lithium-sulfur batteries (Gen 4b/4c/5), supporting the EU’s energy transition. It focuses on deploying a sustainable, high-throughput roll-to-roll (R2R) physical vapour deposition (PVD) process for producing high-purity, thin, and stable LiM anodes at competitive costs. Building on AVESTA’s existing infrastructure, the project will optimise LiM evaporation and protective coating via in situ sputtering, integrate intelligent inline monitoring, high-precision laser cutting, and implement machine learning-based automated quality control. A digital twin (DT) will ensure real-time optimisation, while circular economy strategies will enhance material recovery and recycling at end-of-life.
DMEC, through the dedicated research group at SITEC – Laboratory for Laser Applications, led by Prof. Ali Gökhan Demir, will develop a laser micro-cutting process tailored to the high reactivity of LiM, assessing suitable laser technologies for safe and precise operation.
STELLAR brings together 16 partners from 7 EU countries, including 8 industrial and SME partners (such as AVESTA, AGC, COMAU, AVESTA, HSSMI), 7 academic and research institutions (including CSEM, CID, CEIT, IKER, FhG, UNITO, POLIMI), and one communication and dissemination expert (INOVA). This interdisciplinary consortium covers the entire LiM anode value chain, from research and manufacturing to digitalisation and sustainability. Committed to open science, gender equality, and public engagement, STELLAR is aligned with EU goals for a sustainable and competitive battery ecosystem.