Imagine printing complex ceramic parts like a high-tech inkjet printer, but instead of ink, it uses materials for energy devices. This project makes sure these parts are perfect the first time, avoiding the waste usually seen in factories. It's like having a smart system that catches mistakes before they happen, making green energy hardware cheaper and faster to build.
Manufacturing functional ceramics for energy devices is currently plagued by high waste, high energy consumption, and reliance on critical raw materials like cobalt.
Three industrial MVPs: a 2 kW SOFC stack, a 3.5 kW SOEC stack, and a 1.5 kWh sodium battery module, supported by a Zero-Defect Manufacturing system.
If you are a manufacturer dealing with high scrap rates in ceramic components — this project developed a 2 kW SOFC and 3.5 kW SOEC stack production method that ensures a first-time-right rate of ≥95%. This reduces material waste by ≥80% and energy use by ≥70%.
If you are a battery producer dealing with expensive raw materials like cobalt — this project developed a 1.5 kWh metal-supported sodium battery module using cobalt-free compositions. This lowers strategic dependency on critical raw materials while maintaining high performance.
If you are a supplier dealing with inconsistent quality and high defect rates — this project developed a Zero-Defect Manufacturing loop that keeps defect rates below 5%. This allows for faster production ramp-up and higher overall equipment effectiveness.
Based on available project data, costs are lowered by reducing material waste by ≥80%, saving energy by ≥70%, and achieving a first-time-right production rate of ≥95%.
The project validates industrial-scale MVPs, including a 2 kW SOFC stack, a 3.5 kW SOEC stack, and a 1.5 kWh sodium battery module.
Based on available project data, the project aims for market uptake through the creation of a joint-venture and industrial supply-chain partnerships.
It implements a Digital Product Passport (DPP) and recycling pathways that recover ≥50% of key materials, aligning with EU Net-Zero industry goals.
The project runs from September 2026 to August 2029, aiming to reach TRL 7 for manufacturing routes and TRL 6–7 for the MVPs.
The consortium is heavily industry-driven with a 54% industry ratio, comprising 13 partners across 7 countries. With 7 industrial partners (including 5 SMEs) and 5 academic/research entities, the project is structured for commercial translation rather than pure research, specifically targeting the creation of a joint-venture for market uptake.
Contact FUNDACIO INSTITUT DE RECERCA EN ENERGIA DE CATALUNYA (REC) in Spain
Contact us to connect with the SUMACER consortium for pilot integration.
