For lithium metal solid-state batteries, the presence of defects in the solid-state separator serve as an avenue for dendrite penetration and internal short circuit. As such defects are unavoidable when manufacturing large-scale batteries, new approaches are needed to prevent dendrite penetration. This talk will discuss the use of self-healing separators, where defects are healed passively during cycling, to achieve increased defect tolerance during production and better performance in operation.

Integrating a Co-free/Ni-less high-voltage LiMn1.5Ni0.5O4 (LNMO) spinel cathode in combination with a polymer-based composite solid electrolyte presents a compelling avenue for development of more-advanced solid-state Li-ion batteries (SSLiBs). This class of SSLiBs, which can be produced with a low-cost, scalable process highly compatible with current Li-ion manufacturing, is featured with  high operation voltage (that leads to a simplified pack design), high energy density, excellent safety, and wide operation temperature. In this presentation, Solid Energies Inc. (SEI) will review recent advancements and challenging issues in the course of the transition from lab R&D to commercialization.

Blue Current introduces its pioneering work on fully dry solid-state batteries featuring silicon-based anodes and flexible composite electrolytes. The presentation will provide a detailed exploration of Blue Current's pouch cell performance capabilities, focusing specifically on low-pressure operation that is key for the commercialization of fully dry cells. We will also highlight aspects of the innovative process implemented at the company's 1-2 MWh pilot facility in Hayward.

Anthro’s Injectable Phase Change Electrolyte (IPCE) allows for the production of solid and semi-solid state batteries without changing any manufacturing equipment. This presentation showcases the advantages of IPCE compared to traditional liquid electrolytes with respect to safety, swell, cycle life, and temperature stability in commercially relevant multi-Ah pouch cells. Further, IPCE stabilizes next-generation chemistries such as silicon anodes, reducing capacity fade and calendar aging.

We are highlighting recent key battery technology advancements made using PulseForge flashlamp-based thermal processing tools, including processing of solid-state lithium battery ceramic electrolyte materials within seconds at room temperature. These tools have been used in production for over a decade, and unexpected processes such as soldering on PET have become the new norm. We’ll review the state of the art plus look at the reductions in energy use and cost of operation.

Next-generation battery technologies critically depend on giga factory scale for production of the battery components, such as thin lithium anodes. The core of Arcadium Lithium innovative and sustainable solution is LIOVIX, proprietary printable lithium formulation. The ability to print lithium metal anodes opens the pathway for the various ranges of anode’s width and thickness, and allows cell manufacturer to easier change cell design and format to meet application requirements. Moreover, composite lithium anodes offer improved cell performance, such as longer cycling life.

In this communication, we will present our recent works on battery technologies, especially under the prism of sustainability. Without dismissing energy density, it is necessary for electric mobility to propose sustainable technological solutions at lower prices using less critical raw materials, less solvent for electrode processing, simplified pack design consideration for easier dismantling and longer lifetime. Our journey will cover materials to systems, including not only Li-ion, but also post-Li and non-Li battery technologies. For the latter, we will address sodium- and potassium-ion batteries, in particular.  

Structural battery composites are a unique, multifunctional material, combining both structural strength and energy storage in a single device. Zinc ion batteries are an emerging technology well suited to structural battery applications due to the potential for high-capacity, cost-effective, and non-flammable operation, but still require significant research to maximize their cycling performance and energy delivery. By synthesizing and employing nanocomposite cathode materials, we are able to boost the performance of ZIB devices significantly, which, combined with electrolyte engineering and composite design, allows assembly of structural composite ZIBs with excellent rate capacity, energy density, and structural strength.

Silicon is a promising next-generation lithium-ion battery anode material due to its high theoretical specific capacity; however, its widespread use has been limited due to its severe capacity loss during battery cycling. A rapid, scalable, and novel technique has been developed to coat silicon particles in graphene to preserve the high specific capacity of silicon during battery cycling. Additionally, this methodology can be applied to other materials beyond silicon.

Sodium-ion batteries have garnered significant attention as a potentially low-cost alternative to lithium-ion batteries. In this talk, we assess their techno-economic competitiveness against incumbent lithium-ion batteries. We compare projected price trends across over 6,000 scenarios while varying technology development roadmaps, supply chain scenarios, market penetration, and learning rates.

There has been a significant push to develop electrode materials that meet the diverse demands of modern batteries. Next-generation electrodes present challenges in practical applications, as many of these "new" materials are revisited versions of those abandoned decades ago due to stability issues. New advances in battery electrolytes have sparked renewed interest and understanding. It is an exciting time to apply this new knowledge to address key challenges in Mn-rich cathodes and high Si- or full-Si content anodes.

Low Earth Orbit (LEO) megaconstellations are an emerging market for batteries. SpaceX’s Starlink constellation comprises the majority of all active satellites, with thousands of Starlink Satellites launched in 2024 alone. This talk discusses the unique design, manufacturing, and operating requirements of Starlink batteries compared to typical terrestrial applications, from cell level chemistries to module-level design considerations.

ACT-ion’s clean continuous manufacturing process offers an innovative and cost-effective method to produce cathode active materials (CAMs) for lithium batteries. This method effectively reduces energy consumption and production costs, while also lowering carbon emissions. In this presentation, we provide a comprehensive overview of the advancements in scaling up and commercializing the continuous manufacturing process with highlighting the significant strides made towards implementing this promising solution on a practical level.

Long term cycling results of new active materials, such as silicon based anode, LVPF (LiVPO4F) and LNMO (Li1.0Ni0.5Mn1.5O4) will be discussed in the talk. Specially designed cells are used to maximize the cycling performance of the materials themselves. In addition, the effect of temperature, loading, and particle size are explored to design a cell to reach 500 C-rate discharge capability.