High-Performance Battery Manufacturing

We present the development and manufacturing of a next-generation lithium-ion battery that simultaneously achieves three critical performance attributes: high safety, high energy density (=300 Wh/kg), and ultrafast charging (=6minutes to 80% state of charge), overcoming current trade-offs (high-energy cells charge slowly and pose thermal runaway risks, while fast-charging cells sacrifice energy density). By integrating advanced electrode materials (e.g., silicon and/or TNO composite anodes, high-nickel NMC or lithium-rich cathodes), novel non-flammable electrolytes, and intelligent cell processing compatible with today’s Li-ion production infrastructure, SEI delivers a batch of prototype battery cells being validated for electric vehicle, robotics, consumer electronics, and defense applications.

Sodium-ion batteries are attracting increasing interest due to their cost-effectiveness, sustainability, and supply-chain resilience. This presentation examines degradation in cells with layered-oxide cathodes, hard-carbon anodes, and carbonate electrolytes. Three-electrode measurements are used to assess capacity fade, impedance rise, and voltage-profile changes, while operando X-ray techniques provide direct insight into sodium plating. Gas evolution during pouch-cell testing will also be discussed.

Arbor Battery Innovations’ high-speed laser process introduces 3D vertical diffusion channels into ultra-thick electrodes, decoupling energy density from charge rate. This "drop-in" manufacturing technology integrates seamlessly into existing gigafactory workflows and can be rapidly and inexpensively scaled. Our architecture enables 6C fast-charging in high-loading cells (>300 Wh/kg) while suppressing lithium plating at temperatures as low as -10°C without requiring auxiliary heating.

In this presentation, I will introduce the latest advancements from our 13+ year ARTISTIC research initiative, predicting how manufacturing machinery parameters dictate lithium-ion electrode performance. By coupling rigorous pilot line-validated physics-based simulations with advanced deep learning surrogates, we simultaneously capture macroscopic production machine conditions and local electrode mesostructures. Attendees will discover how this integrated modeling strategy unlocks new pathways for real-time AI-driven process optimization and accelerated battery manufacturing.

Increasing demands on lithium-ion batteries for EV and ESS applications require significant improvements in coated separator performance. In this work, ceramic and polymer coatings are evaluated for their ability to improve thermal stability and electrolyte wettability while maintaining low impedance. Discontinuous adhesive coating designs are investigated for reducing interfacial resistance and enhancing electrolyte accessibility. Correlations between pore morphology, rate capability, and low temperature operation are discussed.

Beff delivers integrated solutions from design to mass production using deep lithium-ion expertise. Beff Navigator accelerates material and cell development with a rapid end-to-end process—from concept and specification design to prototyping, testing, and validation—enabling faster time-to-market. Our professional engineers provide expert support for precise specifications, high-quality prototyping and testing, and advanced analysis, ensuring efficient and reliable development. This presentation will highlight our methodologies and real-world applications using the Beff Platform.

A summary of advanced material development activities at Freudenberg to address the damage and reduced cycle life caused by HF production and salt inhomogeneity.

This presentation will address the safety behavior and underlying mechanisms of SSBs, with direct comparison to liquid-state batteries (LSBs). Testing results show that, during internal shorts in high-energy systems, the severity of fire and explosion follows the order: SSB > LSB. The data indicate a counterintuitive trend—the greater the liquid content in the battery, the safer its behavior under abuse conditions.

Discover how battery and advanced manufacturing companies can identify US sites offering the optimal mix of skilled labor, robust electric infrastructure, top-tier incentives, and tariff protection. This session explores key criteria, emerging hotspots, and strategic considerations for choosing locations primed for growth, resilience, and long-term competitive advantage.