Lithium-ion Battery Development & Commercialization

Inorganic cathodes face challenges of cost, supply risk, and environmental impact, underscoring the need for new chemistries. This talk introduces TAQ-a crystalline, all-organic cathode material that eliminates reliance on critical metals while delivering high energy density, long cycle life, and safety across multiple metal-ion systems. The presentation will also outline Daqus Energy’s efforts to commercialize this next-generation battery technology.

The next-generation of energy storage is being driven by breakthrough solid-state battery technology that overcomes the fundamental limitations of conventional lithium-ion batteries, enabling longer range, faster charging, and enhanced safety through advanced ceramic separator technology. The current challenge facing those developing this technology is commercialization at a global scale to meet the massive global battery demand. This presentation addresses the unique commercialization strategies to bring this technology to market.

Ensurge Micropower is advancing high volumetric energy density (VED) anodeless all-solid-state lithium micro-batteries, built on ultra-thin stainless steel foil that deliver compact form factors, rapid charging, and high pulse discharge tailored for wearables, hearables, and IoT applications. These micro-batteries use an anode-less architecture and are SMT compatible while leveraging unique packaging and stacking technology. This study showcases the advancement of micro-battery technology from research to manufacturing enabled by innovations in materials engineering, roll-to-roll processing, and multilayer stacking. Emphasis is placed on process integration, yield optimization, and advanced testing that bridge laboratory development and high-volume production, for reliable, high-performance micro-batteries.

Cathode microcracking is a significant problem, especially for Ni-rich NMC and NCA that are commonly used in automotive cells. We need ways to assess the effectiveness of strategies that prevent microcracking—ideally using non-destructive methods that can be used on commercial cells. In this work, we use in-situ x-ray imaging and diffraction to characterize how microcracking affects the microstructure and function of commercial cells that have been cycled for years, including a single-crystal NMC cell that has been cycled 20,000 times over 6 years.

All-solid-state lithium batteries (ASSBs) offer enhanced safety and energy density, but progress remains limited by the challenge of developing high-energy-density cathodes and solid electrolytes (SEs) that are both highly conductive and electrochemically stable against lithium metal anodes and high-voltage cathodes. Here, we report the synthesis of ceramic–polymer composite SEs with high ionic conductivity and low activation energy using industrially compatible roll-to-roll manufacturing and rapid photonic processing. Development of high-mass-loading composite cathodes, integration with SEs, and the resulting cell performance will be presented. 

Future generation lithium batteries are expected to conquer multiple frontiers, including increased energy density, faster charging, greater safety, and lower cost. While several new active materials continue to achieve higher levels of technology maturity and readiness, there are no commercially available electrolytes that are tailored for these systems. Feon pioneers a novel pharma-inspired approach to developing and tailoring new molecules and electrolyte formulations to unlock breakthrough performances for advanced lithium batteries.

LMR cathode active materials historically exhibit persistent voltage and capacity fade, and typically require tailored electrolytes that are functional at high potentials. Stratus Materials has developed a scaled a low-cost processing route that locks in an exceptionally stable entropic crystallographic state in cobalt-free LXMO.  Data will be disclosed that shows LXMO-based large-format cells (20Ah and larger) can have energies of over 700 Wh/l, and cycle-life stability of over 2000 cycles.

Ultra-thin lithium metal foils are essential as an anode for achieving high-energy density in lithium rechargeable batteries. However, current manufacturing methods are hindered by high cost and low productivity, resulting in an expensive and limited supply chain. As a specialized lithium metal manufacturer, we have successfully developed a processing technology for producing ultra-thin lithium metal foils, even down to several micrometers thickness via a low-cost and mass-producible rolling process. Furthermore, the advanced rolling process is also beneficial in producing surface-modified lithium metal foils with superior anode performance through an in-situ surface treatment during the rolling process.

Sulfide solid-state electrolytes combine high ionic conductivity with favorable mechanical properties but are often considered too moisture-sensitive for scalable processing. Using Na3PS4 as a model, we developed a custom humidity-controlled glovebox (1–50% RH) to systematically evaluate its moisture tolerance. Our study reveals a surprisingly high critical humidity threshold below which Na3PS4 retains recoverable ionic conductivity and stable cycling. Distinct reaction pathways at varying humidity levels further clarify degradation and recovery mechanisms. These findings define a practical process window and provide quantitative guidance for cost-effective manufacturing of high-performance solid-state batteries under moderate, rather than ultra-dry, conditions.

A novel, purely physical roll-to-roll (R2R) process enables scalable, cost-efficient production of stable silicon anodes for lithium-ion batteries without silane. Silicon is directly deposited onto copper current collectors and subjected to an ultra-short, high-intensity flash. This treatment generates targeted defect structures, local passivation, and modified lattice properties – effects well-known in semiconductor physics but largely overlooked in battery development. These transformations mitigate mechanical and chemical degradation, stabilizing the anodes. Combining industrial R2R manufacturing with precise material control, this approach establishes an innovative, scalable route for high-energy-density silicon anodes, paving the way for next-generation lithium-ion cells that are high-performance and long-lasting.

All-solid-state lithium metal batteries promise step-change improvements in energy density, but scalable manufacturing of lithium metal anodes has remained a key bottleneck. This talk traces the transition from glovebox-based prototyping to roll-to-roll production, highlighting advances in lithium anode handling, assembly, and integration under dry-room conditions. These innovations enable high-throughput production of lithium metal batteries using processes increasingly compatible with existing lithium-ion manufacturing lines.