The Math2Market GmbH carried out a four‑year research and development project from 1 May 2019 to 30 April 2023, later extended by six months in agreement with its partners. The project, funded under the German grant number 03ETE018B, focused on the simulation‑based design and evaluation of high‑capacity battery electrodes and cells. Its core deliverable was the development of a fully integrated digital workflow that combines image processing, geometric modelling, physical modelling and electrochemical simulation. The workflow is embodied in the commercial software GeoDict, which was enhanced with a new, faster and more memory‑efficient numerical solver, and with the BESTmicro electrochemical solver from Fraunhofer ITWM. Together, these tools allow the creation of digital twins of battery electrodes, the simulation of Li‑plating and solid‑electrolyte interphase (SEI) growth, and the optimisation of electrode performance and cycle life.

In the first sub‑task of the project, partners from the German Aerospace Center (DLR) and Fraunhofer ITWM developed and implemented physics‑based models for Li‑plating and SEI growth. These models were integrated into the simulation engine and validated against experimental data. The second sub‑task saw Math2Market engineers create flexible, efficient structure generators that enable the design of structured electrode concepts. A key technical achievement was the implementation of an anisotropic diffusion solver for graphite anodes, which captures the directional dependence of lithium transport and improves the fidelity of ageing simulations. The third sub‑task applied the developed tools to industrial partners: Volkswagen (later PowerCo) and SGL Carbon used the workflow to simulate homogeneous electrodes and simple structuring concepts with various active materials. The results guided the optimisation of novel structured electrode designs, improving both power density and cycle stability.

The project also advanced image‑analysis capabilities. High‑resolution micro‑CT scans of model electrodes, performed by the external service provider RJL Micro & Analytics, were imported into GeoDict. Within the software, image‑processing algorithms were refined and augmented with machine‑learning techniques to automatically segment electrode microstructures. These digital twins were then validated by Dr. Roman Buchheit and used to benchmark the simulation results. The integration of image‑based geometry with physics‑based models is unique in the market and constitutes a commercial product that combines geometry analysis, modelling and simulation in a single platform.

Collaboration was central to the project’s success. The core team at Math2Market, led by Dr. Mathias Fingerle, worked closely with researchers from Fraunhofer ITWM, DLR, the Hochschule Aalen, and industry partners Volkswagen (PowerCo) and SGL Carbon. The project maintained a stable personnel structure; key contributors included Dr. Janine Hilden, Dr. Anja Streit, Dr. Ilona Glatt, Dr. Fabian Biebl, Dr. Rolf Westerteiger, Dr. Sven Linden, and Dr. Roman Buchheit. Computing resources were provided by Math2Market’s own infrastructure, ensuring uninterrupted simulation runs. A joint publication with the Hochschule Aalen was produced, and the partnership with Fraunhofer ITWM continues to evolve the BESTmicro technology.

Overall, the project delivered a unique, end‑to‑end digital workflow that enables rapid design, simulation and optimisation of battery electrodes. The integration of advanced image processing, structural modelling, and electrochemical simulation, together with validated physics‑based degradation models, provides a powerful tool for the battery industry to accelerate the development of high‑performance, long‑lived cells.