Enabling Scalable Structural Battery Composite Production: Key Considerations and Possibilities

Paper in proceeding, 2026

Extended electrification in transport and product segments requires lightweight and energy-efficient solutions that also allow for increased design flexibility. Structural battery composites meet these needs by combining mechanical load-bearing capability with energy storage in a single multifunctional material. This study focuses on structural battery composites made from carbon fiber reinforced polymer (CFRP) and evaluates their manufacturing methodology. Using a SWOT analysis framework, the manufacturing process was analyzed with respect to production scalability, manufacturing possibilities, and the triple bottom line—covering environmental, social, and economic sustainability.

The analysis identified key strengths in flexibility and design freedom, but also weaknesses such as high initial costs, labor-intensive workflows, and limited recyclability of materials. The results indicate that the current method is suitable for low-volume, highly customized production, while large-scale implementation is restricted by process sensitivity and high material costs. To progress toward industrial-scale manufacturing, future development should focus on automation, sustainable material alternatives, and improved recyclability to enable a scalable and environmentally viable production process.