No grippers, No E-Mobility

The battery industry has grown significantly in recent years. However, growth rates vary considerably depending on the region and metric: Individual markets, such as Germany, have seen massive growth over the past five years, and global production capacity has also increased substantially. At the same time, the design of new cell manufacturing facilities has slowed recently, primarily due to project delays, cancellations, and increasing market consolidation in Europe and North America.

Despite these short-term setbacks, the long-term outlook remains positive. Demand for batteries is expected to continue rising in the coming years, driven primarily by electric mobility, stationary energy storage, and industrial applications. By 2030, the share of battery electric vehicles (BEVs) in new vehicle registrations worldwide is expected to climb to about 30 percent or more—and in some regions, significantly higher. Growth remains strong, but many current forecasts indicate a somewhat more moderate pace than earlier projections. At the same time, demand for internal combustion engines continues to decline, albeit more slowly than expected in the most optimistic scenarios.

The market in China is growing particularly rapidly: By 2025, the share of BEVs among new vehicle registrations there was already significantly higher than in Europe. Chinese manufacturers have long been setting their sights on international markets and are significantly expanding their export presence, while many European projects still need time to ramp up.

The battery will determine the future of the automotive industry. It dictates the range, charging time, and cost of an electric vehicle. At the same time, it is emerging as a strategic factor of power for entire national economies. Those who produce batteries ensure industrial value creation, technological expertise, and jobs. Europe is therefore under pressure. The continent must design its own production capacity if it wants to hold its own in global competition.

“The battery is a key technology,” says Patrick Schneider, International Industry Segment and Key Account Manager for Batteries at Schmalz in Glatten. “Depending on the model, it accounts for a significant portion of a vehicle’s cost. For European industry, therefore, this is about much more than just individual factories. It’s about resilience, security of supply, and the capability to actively shape the mobility transition.” At the same time, the battery plays a central role in the European Union’s climate goals. Without widespread adoption of electric vehicles, the decarbonization of transportation will be nearly impossible to achieve.

But the path to a high-performance battery requires high-precision manufacturing processes. That’s exactly where Schmalz comes in. The vacuum technology specialist views battery production as an end-to-end value chain: from cell manufacturing through module assembly to the finished pack. Every step requires maximum precision, a high level of safety, and efficient automation.

Cell manufacturing is particularly challenging. In a process known as “stacking,” the anode, separator, and cathode are positioned precisely on top of one another. Even the smallest errors can later reduce the battery’s power, as electrodes are sensitive to pressure marks or damage. Specialized area and suction cup grippers from Schmalz move the components accurately while leaving few marks.

Another risk often lies in the details: metal contamination. Tiny particles of copper, nickel, or zinc can compromise the quality of a battery cell. Schmalz has therefore reduced the presence of precisely these metals to a technical minimum in the SCPSb, SCPSc, and SCPSi-BY ejector series. This lowers scrap rates and increases process reliability in sensitive production environments.

Schmalz also relies on robust and practical systems for module and pack assembly. For round cells with a diameter of 46 millimeters, many manufacturers use the bistable magnetic gripper SGM-SV-BY. The technology operates reliably and has proven itself under demanding conditions. In addition, there is the battery module gripper, a plug and play system solution that moves complete modules and inserts them into the battery case from above. This enables a particularly high packing density and thus potentially greater range for electric vehicles.

Safety is the top priority here. “There can be no compromises when it comes to batteries,” emphasizes Patrick Schneider. Errors not only jeopardize production processes, but also endanger people and equipment. That is why Schmalz uses redundant vacuum supply systems and develops systems for critical loads that offer maximum protection against failures.

This is precisely where an opportunity lies for Europe. Asia—especially China—currently dominates battery production. However, European companies can leverage their strengths in intelligent automation, sustainability, and resource-efficient manufacturing. Every efficiently produced battery strengthens Europe’s industrial competitiveness and moves the mobility transition one step forward.