Fast lane for battery cell production

The future of battery production starts here. At the Fraunhofer Research Institution for Battery Cell Production FFB, teams develop economically and environmentally sustainable battery cells. Siemens supports FFB with innovative production technologies and software.

The first phase of the project is the “FFB PreFab.” Just outside Münster, several interdisciplinary teams are working with industry and project partners to research how new battery technologies can be produced in Germany more efficiently, sustainably, cost-effectively, and to the highest quality.

As a “research factory,” the FFB PreFab not only brings science, theory, and practical application together but also actively advances them. The laboratories and production lines will help optimize equipment, digitalization technologies and cell designs from pilot scale to industrial scale as well as enhance manufacturing methods and processes and, last but not least, train urgently needed specialists.

Scalable production

FFB PreFab enables scalable battery production from research to industrial level. Flexible systems and digital planning allow rapid testing and expansion of new technologies for efficient ramp-up and future scaling.

Data integration

Seamless data integration across systems ensures transparency and consistency. By linking machines, processes and digital tools, the FFB PreFab builds a unified data base for better decisions and continuous improvement.

Sustainable manufacturing

Sustainability is central to the FFB PreFab, where efficient processes, optimized resource use and digital solutions enable environmentally responsible battery production while supporting long‑term climate and energy goals.

The FFB PreFab was officially opened on April 30, 2024 by representatives from North Rhine-Westphalia, the Federal Government, the city of Münster, the Fraunhofer-Gesellschaft and the Fraunhofer FFB management (from left to right: Silke Krebs, Ina Brandes, Bettina Stark-Watzinger, Hendrik Wüst, Markus Lewe, Prof. Dr.-Ing. Holger Hanselka, Prof. Dr. Achim Kampker, Prof. Dr. Jens Tübke, and Prof. Dr. Simon Lux).

Shaping sustainable transformation

The FFB PreFab has two goals, which are also important guidelines for Siemens in its corporate entrepreneurial activities: enabling innovation and accelerating the digital transformation for a sustainable future. Battery and storage technologies will be critical to the success of the energy and transportation transition and will make a significant contribution to the achievement of climate targets. With its expertise and decades of experience, Siemens is an integral part of the ecosystem of local value creation in electromobility.

As a project partner of Fraunhofer FFB, Siemens is supporting the facility, based on the open digital business platform Siemens Xcelerator, with software and hardware solutions for building automation and production systems – and above all a comprehensive digitalization model that will digitally map the entire research factory, from the building automation and control equipment to the production lines with all the process steps.

Scalable, flexible production architecture

The deep integration of OT (operational technology) and IT (information technology) is an essential prerequisite for investigating and optimizing a wide variety of technologies and materials under real-world and industry-oriented conditions in the FFB PreFab.

This OT and IT integration allows machines from different manufacturers to be integrated into a flexible line design and, through the standardization of automation and interfaces, creates the conditions for the interoperability of the systems – important criteria for a research production facility in which innovative production scenarios will be business as usual.

Solutions for the Industrial Internet of Things

Space for innovation: the FFB PreFab houses a complete battery cell production facility for the production of pouch cells and prismatic cells for research purposes on an industrial scale.

By implementing the Manufacturing Execution System (MES) and the IIoT (Industrial Internet of Things) platform, Fraunhofer FFB is able to plan, control, optimize and flexibly scale production processes. With the building management platform Desigo CC Siemens will automate, among other things, the entire FFB PreFab building, including the clean and drying rooms, which cover around 1,000 square meters. A state-of-the-art manufacturing execution system (MES) and a flexible production management system will bring the various processes and data together and make them available to the teams.

The Production Management for Batteries production management system, based on SIMATIC WinCC OA, is an Industrial Internet of Things (IIoT) platform that collects data from the machine and process level and makes them available to higher-level systems such as MES and IT applications. The order information is processed in the Siemens Opcenter Execution MES and transferred to the machines via the IIoT layer. The data from the machines and systems are networked via a standardized information model so that all information is available along the entire value chain. Battery-specific use cases and libraries ensure efficient and standardized engineering of the functions.

Battery technology is a key technology of the future. With the FFB PreFab as an open battery cell factory for research and development, we are making an important contribution to advancing the production of battery cells in Germany. In this way, we are not only addressing international market demand but also helping to successfully establish Germany and Europe as a leading international technology hub for the long term.

Prof. Dr. Simon Lux, Managing Director, Fraunhofer FFB

From the FFB PreFab to the FFB Fab

According to Markus Birkhan, Head of the Battery Vertical at Siemens AG, the result will be nothing less than a revolution in battery cell production. “Together with Fraunhofer FFB, we want to take the battery industry in Germany to the next level.” By this, the expert means capacity that can be quickly expanded, optimum production quality, and a reduction in rejects thanks to transparent processes and the ability to quickly scale up new or alternative battery technologies.
The FFB PreFab is an important step toward the construction of the FFB Fab, which will create 20,000 square meters of additional production and research space and enable industry-oriented production research and development in the gigawatt range with system technology on a large industrial scale. Münster will thus finally become Europe’s “Battery City.”

Project partnership for integrated battery production

Fraunhofer FFB and Siemens are driving forward the standardization and integration of processes and systems in the FFB PreFab in other projects. The project partners are thus clarifying important questions in research and development, but also in the production of battery cells, such as, how can data, interfaces and interaction in battery cell production be standardized? What are the benefits of edge technologies for process and quality control? What will a flexible, scalable and secure data exchange platform for the technical implementation of a comprehensive digitalization strategy for the efficient and sustainable use of battery data look like? And last but not least: How can the digital twins of the product, systems, and building be combined to create a comprehensive digital image of the entire factory?

The FFB PreFab houses laboratories and a complete battery cell production facility with innovative European machine technology on around 6,450 square meters of research space.

Data-based models and optimizations in modern production are only as good as the underlying data quality. Effective integration of IT and OT systems is required to ensure high data quality in battery production. Consistent battery production standards simplify this integration process and are essential for scaling up to the gigafactory level.

Arno Schmetz, Group Leader, Data Acquisition and Aggregation, Fraunhofer FFB

Expertise for tomorrow’s battery cell production

Siemens is supporting the Fraunhofer FFB project with these solutions and systems, among others:

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Factory and process planning

Simulation is a key element of the FFB PreFab digitalization strategy, connecting planning, development and production. Digital factory, line and logistics models enable early validation, optimization and risk reduction, supporting flexible, efficient and scalable battery cell manufacturing.

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Manufacturing execution system

Manufacturing operations management connects planning, engineering, and production in real time. As the core of the FFB PreFab digital ecosystem, it enables transparent, data-driven operations, continuous optimization, and scalable, high-quality battery cell manufacturing.

IIoT platform

Supervisory control and data acquisition provides a unified platform for real-time monitoring, visualization, and control across the FFB PreFab. It ensures transparent operations, seamless data flow, and reliable decision-making, supporting efficient and scalable battery cell production.

Desigo CC

At Fraunhofer FFB, Siemens uses Desigo CC to automate and manage the entire PreFab facility, including clean and dry rooms. The platform integrates building systems, ensures operational transparency, and supports efficient, scalable, and sustainable battery cell production.

Digital Infrastructure

Siemens helps Fraunhofer FFB build the battery factory of the future by integrating digital planning, automation, building management, and production systems. This connected infrastructure improves efficiency, sustainability, and the scalability of battery cell manufacturing.