Faraday Institution – £9m for Battery Formation and Ageing

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The UK’s race to build a competitive battery industry has often focused on gigafactories, supply chains, and skills. But there’s another stage of battery production that rarely makes headlines — formation, ageing, and testing (FA&T). These processes, carried out in the final stages of cell manufacturing, are time-consuming, energy-intensive, and expensive.

The Faraday Institution has announced a £9 million investment into two new projects targeting these exact bottlenecks.

Why FA&T matters

When a battery cell is assembled, it isn’t ready to use immediately. It must undergo formation — carefully charging and discharging under controlled conditions so its electrochemistry stabilises. It must then be aged and tested to ensure it performs safely and consistently. These stages can take up to 30% of total production time and consume vast amounts of energy.

Cutting costs here could reduce battery prices significantly — crucial if the UK is to remain competitive with Asia, where FA&T processes are already highly optimised.

What the projects aim to do

1. Optimise chemistries: The research will explore how different electrode formulations (particularly graphite-silicon anodes and high-nickel cathodes) can reduce formation time.

2. Model electrochemical behaviour: By combining AI with advanced modelling, the aim is to predict how cells will age, cutting the need for lengthy testing cycles.

3. Automate testing: Smarter algorithms and digital twins will allow for rapid feedback and quicker rejection of underperforming cells, reducing waste.

Why it matters for sustainable manufacturing

Every hour shaved off FA&T saves energy. Every cycle of testing removed reduces waste and scrap. More efficient FA&T therefore lowers the carbon footprint of battery production while also improving economics.

If successful, this research could enable UK gigafactories to produce cells faster, cheaper, and with less environmental impact.

Lessons for industry leaders

Even outside battery manufacturing, there are takeaways:

• Final stages matter: Don’t overlook downstream processes in your own production. They can be as costly and impactful as the main line.

• Use modelling to cut trial-and-error: Digital twins and AI can simulate outcomes faster and with fewer wasted resources.

• Collaborate across sectors: This project combines universities, industry, and government. Complex bottlenecks rarely get solved in silos.

Conclusion

The Faraday Institution’s £9m investment may seem modest, but it addresses one of the least glamorous yet most crucial aspects of the battery value chain. For the UK to lead in sustainable battery manufacturing, tackling inefficiencies in FA&T is just as important as building gigafactories.