Success Story #6 | From Lab to Cell: Integrating Ultra-Thin Sensors into Li–S Pouch Cells

HEALING BAT has taken the first integrative step toward “sense‑and‑repair” cells by moving its 30‑micron‑thin prototype sensors from the lab onto battery pouch‑cell integration paths, linking WP3 sensor development to WP4 prototyping and advanced analytics. 

This milestone marks one of the first real demonstrations of how next-generation embedded sensors can monitor Li-S cells, strengthening Europe’s leadership in smart battery technologies. 

A collaborative milestone

• Coventry University specified the interfaces needed to link sensing signals with battery management systems, ensuring data usefulness at pack control level.  
• CPI combined materials expertise with a lithographic fabrication route and barrier encapsulation to preserve function and isolation within the cell environment.  
• The consortium aligned on a model cell to streamline design for integration and test protocols. 

This shared model cell accelerates reproducibility and lays the foundation for reliable performance benchmarking across partners. 

Integration pathway underway 

HZB has received dummy prototypes to develop the mechanical and process integration of the sensing layer in Li––S cells. These trials will inform WP4 procedures for cycling, advanced analytics, and definition of self‑healing markers and triggers, a prerequisite to close the loop with WP5 (BMS & Digital Twin). These early integration trials will directly feed into a more predictive, data rich BMS, increasing the long-term safety and durability of Li-S technologies. 

Toward a “sense and repair” toolbox 

 
By combining self-healing materials, in-cell sensors, and a bespoke BMS, HEALING BAT aims to detect early degradation events and initiate corrective/healing responses, moving batteries from passive devices to active, self-monitoring, self-healing systems.  

This integrated approach is positioning HEALING BAT as a reference initiative for smart, autonomous battery systems under the BATTERY2030+ vision.