Comparative Cost–Benefit Analysis of Additive Manufacturing and Tool-Based Manufacturing for Battery Cell Housings in Low-Batch-Size Production

This paper explores the economic feasibility of Additive Manufacturing (AM) for producing prismatic battery cell housings, specifically targeting small production runs. A comprehensive cost analysis was conducted to compare AM with Tool-Based Manufacturing (TM) processes for battery cell caps and cans. This analysis takes various factors, including tooling, materials, machinery, labor, and part finishing costs, into account. The study demonstrates that AM offers significant economic advantages over TM for single-digit and low double-digit batch sizes, primarily due to the absence of expensive tooling costs associated with TM. AM-produced battery cell cans continue to be cost-effective even for medium-sized production runs. Additionally, AM allows for the integration of sensors directly within battery cell caps, providing enhanced real-time monitoring capabilities–an important benefit for development purposes. Further analysis, assuming a best-case scenario, indicated potential cost savings through the use of increased layer heights and faster recoating and scanning speeds, which enhances the economic appeal of AM. Overall, the findings suggest that AM is particularly beneficial for the production of battery cell housings in low- to mid-volume ranges, emphasizing its strategic importance for flexible manufacturing requirements and research-intensive applications.