Global Battery Manufacturing Production

This work presents an in-situ diagnosis system of large capacity lithium-ion battery based on a sponge-type battery swelling sensor, which is appropriate for battery module-level integration. In addition, developed swelling sensor was applied for battery cell and module level monitoring. The sensor could monitor the battery swelling under changing state-of-charge (SOC) with various current rates (C-rates) from 0.1C to 2C. It also demonstrated early risk detection performance that can reveal the thermal runaway of the battery module at least 1500 seconds ago, by sensing the abnormal swelling.

Chinese solid-liquid hybrid battery production exceed 30 GWh in 2025, and it has entered multiple application markets and EV batteries. Dry coating process, direct molding, and pressurized during production have been used and are being further considered as technology options for future all-solid-state battery production. This presentation will give and introduce the latest status of relevant process technologies in China in 2026.

Traditional CT scanning has been limited to a handful of cells per lot due to time and cost constraints, leaving battery lot qualification statistically underpowered and vulnerable to undetected defects. This presentation details a collaboration between NASA and Glimpse to CT-scan 200 cells from a 60,000-cell flight lot, revealing electrode overhang violations and metallic particle contamination that a conventional 14-cell sample would almost certainly have missed. Statistical analysis shows that 200+ scans are required for ≥90% confidence at 1% defect rates—a threshold now achievable with hig.

Conventional slurry mixing and wet coating rely on energy-intensive drying, driving significant capital costs, energy consumption, and carbon emissions in battery manufacturing. This talk presents Anaphite's Dry Coating Precursor (DCP) process, with case studies demonstrating how engineered composite electrode materials enable scalable dry coating while maintaining high electrochemical performance. The approach provides a practical pathway for cell manufacturers to adopt dry coating at industrial scale.

Li-ion cells have achieved a remarkable record for calendar life as confirmed by testing of cylindrical, prismatic and pouch cells manufactured by PolyStor Corporation in Livermore, CA in 1997 through 2001 and recently tested. This paper reports the test results on these cells, including performance, cycling and Electrochemical Impedance Spectroscopy results. It also reviews design, chemistry and manufacturing of these cells and confirms their performance after more than a quarter of a century. It will review the criteria necessary to achieve such extended life in commercially manufactured Li-ion cells.

A battery management system (BMS) chipset with built-in Electrochemical Impedance Spectroscopy (EIS) may bring lab-grade diagnostics into vehicles. These features may be used to support fast charging current setting and temperature monitoring in a faster, safer, and more accurate control loop. This presentation will explore the reality of implementation.

When battery companies are small, problems surface early. Teams share context, assumptions travel with decisions, and feedback is immediate. As companies scale, something breaks long before chemistry or equipment: visibility. Teams multiply, timelines compress, and experts are asked to see more with less time. Leading global battery companies compensate with thousands of engineers. Most startup companies cannot. This talk explores how optimized feedback loops, lifecycle traceability, digital twins, and physics-aware AI help limited experts detect risk earlier, align decisions across silos, and scale without losing control.

Advanced electrode architectures for pouch and cylindrical battery cells were developed and validated. Key achievements include high-power ultrafast laser processing enabling parallel structuring and significant throughput upscaling for thick-film electrodes. Structural patterns for cathodes and anodes are optimized to enhance discharge and fast-charging performance and mitigate lithium plating. Large-area 3D elemental mapping provides binder distribution analysis after coating and post-mortem degradation analytics, establishing a versatile tool for electrode architecture optimization. Laser processes for electrode development targeting solid-state battery applications are under investigation with upscaling as a key objective.

Scaling battery cell manufacturing from lab-scale processes to pilot and industrial production is often limited by process robustness, equipment transfer, yield stability, quality control, and data availability. This presentation discusses the key pain points across the process steps and highlighting where the largest optimization potential lies. It outlines opportunities to improve manufacturability, reduce scale-up risk, and accelerate industrial manufacturing readiness.

Battery metals markets are showing preconditions for tighter fundamentals. Demand remains supported by EVs, energy storage, and downstream investment, while supply faces uncertainty from geopolitics, trade realignment, and execution risk. This session assesses whether price movements signal a tightness cycle, which metals are most exposed, and how supply can respond.

This presentation will discuss a three-dimensional approach for battery-materials reclamation: deactivation, direct recycling, and design. The service of lithium-ion batteries and recycling of their materials is at the forefront of the reestablishment of the global supply chain of critical-materials refining and manufacturing. The industrialisation of this requires innovative processes and design to realise cost and safety demands in the next generation of lithium-ion manufacturing.

This session takes a deep dive into the Battery Talent Census, offering a sneak peek at emerging workforce data and what it signals for the industry through 2027. We'll explore the trends reshaping how battery companies hire and how professionals build careers, from shifting skill demands to evolving compensation dynamics across the value chain. Whether you're scaling a team, planning your next role, or simply trying to understand where the talent market is heading, you'll walk away with practical insights to hire more efficiently, position yourself competitively, and navigate the workforce shifts defining the next chapter of battery growth.