Electric Vehicle Battery Technologies

It's often said that #batteries are resource intensive, but more than 95% of the key minerals can be profitably #recycled. Redwood Materials is doing just that, with the first closed-loop battery recycling plant in the US, and probably the world. Started by Tesla co-founder JB Straubel, Redwood plans to produce enough recycled battery material to build more than 1.3 MILLION EVs a year by 2028. This is a turning point for the US battery supply chain. China currently controls 70% of the planet's lithium refining capacity and up to 95% of production for other crucial materials needed to make EVs. Redwood is attempting to break that stranglehold. Redwood's 300-acre industrial campus is impressive. Nothing goes to landfill, and no water leaves the site apart from sanitary waste from toilets and washbasins. There are no gas lines, everything is electric. And the place is built for scale: 30 acres of old batteries are sitting ready to be fed into the process. That process begins with an enormous slow cooker, baking the material at about 300°C for an hour. There is no combustion - it doesn't use any oxygen. There are no emissions - gases are trapped and made into industrial products. It also uses very little electricity. Once the kiln heats up, the energy released from the batteries is self-sustaining, like a continuous, slow, controlled version of a battery fire. A new analysis by Stanford University researchers (admittedly still in peer review) found that Redwood's recycling process produces up to 80% fewer emissions than the traditional supply chain using refineries that belch out CO2. And this is what circularity looks like folks. Once the entire vehicle fleet is electric, and all the necessary minerals are in consumption, we'll only have to replace a few percent each year that are lost in the process. It will become obvious that it doesn't make sense to keep digging stuff out of the ground. Link to full story is in the comments below. #energy #sustainability #renewables #energytransition

Why does your phone battery die in 3 years, but car companies can give lifetime warranty on your EV’s battery? Because even though both say “lithium,” they’re not the same chemistry. 📱 Your phone: Most smartphones today use Lithium-ion batteries with graphite anodes. 1. Limited energy density → the battery can only pack so much power in that tiny slab. 2. Heat build-up during fast charging → accelerates degradation. 3. ~800–1000 charge cycles before capacity falls to 80%. That’s why after 2–3 years, you start carrying a power bank. 🚙 Your EV: Next-gen EVs are moving to Silicon-carbon anode batteries. 1. Silicon can hold almost 10x more lithium ions compared to graphite. 2. Carbon is added to balance expansion and improve stability. Results: higher energy density, cooler operation, and almost double the cycle life (~1600+). That’s why an EV can be confidently backed with 7–8 years (sometimes even lifetime) warranties. As costs fall, the same tech that powers cars will eventually redefine what “battery life” means for everything else you own. So the next time your phone dies in year three, don’t just blame “planned obsolescence.” The truth is simpler: it’s not the app updates killing it. It’s the material limits of the chemistry inside. At the end, everything has an expiry date. The only question is how far science can push it.

What are the next big #trends in #battery technology? Development is progressing at a rapid pace. It is difficult to keep track of everything. Scientific overviews and strategy documents are of great value.  💡 The European Strategic Research & Innovation Agenda (#SRIA) of the Batt4EU Partnership summarises the most important research topics from the perspective of the European Battery R&I community. The SRIA also provides the basis for the development of the Horizon Europe research programme. 👍 Furthermore, I recently came across a paper by Achim Kampker et al. in which they summarised and excellently visualised the technological trends in the battery industry. The priority matrix and hype cycle curve are also taken from the paper. 🚀 They identify a few must-have solutions for the nearer future: * #Silicon graphite composite anodes are already being offered by the first manufacturers. * #LFP cathodes are already the dominant battery cell chemistry, and LFMP and blends with NMC are nearing market launch. * Blade cells are becoming the new standard #format for LFP-based cell chemistries, and production of the 4680 round cells is also beginning.  * #Drycoating still has some technical hurdles to overcome before the technology is ready for mass production. However, there are increasing signs that we are getting closer to market launch. 💸 The big challenge for battery manufacturers is that a factory built with today's technology will be outdated tomorrow. For the #businessmodel to work anyway, there needs to be a market that demands batteries and allows for mixed costing. At the moment, we are seeing industrial overcapacity in China in particular and a slowed demand growth globally. In particular, manufacturers with a relatively old factory portfolio and insufficient international diversification are suffering as a result.  Further information: * SRIA: https://lnkd.in/eJgNECA7 * Paper: https://lnkd.in/exYuqNjn

Designing a smarter retirement for batteries: The Digital Battery Passport In ABC Australia’s TV show Utopia, actor Rob Sitch quips: “Every element in the process is intelligent, but as a whole it is ridiculous.” That could describe today’s lithium-ion battery recycling system. It is a patchwork of innovation trapped in systems that forget the big picture. The challenge is not innovation but integration. Across mining, refining, manufacturing, regulation, and recycling, progress happens in isolation. The result is a technically brilliant but disconnected ecosystem. The fix is digitisation and collaboration, connecting engineers, data scientists, policymakers, and industry through digital tools such as the Digital Battery Passport. At RMIT University, we are developing Australia’s first Digital Battery Passport, a secure blockchain based record that traces each cell’s chemistry, performance, ownership, and event history. Our work is funded by the Australian Government’s AEA Ignite initiative and has more recently received further support through its Quad Clean Energy Supply Chain Diversification Program. Think of the passport as a digital birth certificate and retirement plan for batteries, dynamically adapting to supply chain changes, national priorities, and sustainability targets. Now, I might not speak fluent Python, but I do speak battery. I understand how cells are built, how they age, and why they fail. I also understand what the shift from nickel and cobalt rich chemistries toward the good old lithium iron phosphate (LFP) cells means for the recycling world: safer, cheaper batteries with far fewer high value metals, challenging traditional recycling economics. Our AI models interpret unstructured multi modal battery data, from factory test sheets to in-field performance logs, automating workflows to reduce human intervention. They predict health, classify materials, and flag optimal pathways for reuse or recovery. In the rapidly growing second hand Electric Vehicle market, this capability is invaluable: a digital battery certificate generated from passport data verifies the health and history of a used vehicle’s battery, giving both buyers and regulators confidence in its safety and remaining life. Looking ahead, we are extending these capabilities to recycling plants, where AI will fine-tune process parameters in real time and optimise material recovery with minimal waste. By giving every cell a digital identity, we can turn what would be waste into a data-rich asset, making the global battery supply chain cleaner, fairer, and more resilient. As Rob Sitch might say, it’s about making the whole as intelligent as its parts. Giving batteries a second life and a digital identity, isn’t just recycling. It’s reimagining responsibility in the age of electrification. Interested in collaboration? Get in touch: https://lnkd.in/gM-tktFV

We are beginning to see evidence of new EV battery plants’ production coming online based on Census Bureau data on value of shipments for battery manufacturing plants (https://lnkd.in/g2HD7KN7), adjusted for inflation with the Bureau of Labor Statistics’ producer price index for that sector (https://lnkd.in/gr8EBs7X). Below I’ve converted inflation adjusted value of shipments to an index where 100 = 2019. Seasonally adjusted value of shipments are utilized. Thoughts •November 2022 is the first month where we see inflation adjusted shipments show a breakout, which has subsequently increased. The peak of the series so far was March 2023, where inflation adjusted shipments were ~50% above 2019 levels. This is quite an increase in domestic production of batteries over a short period. •Given the huge pipeline of EV battery plants in the USA, there is little doubt that this series will continue to increase sharply over the coming years (e.g., I expect we will see readings of 200+ for the index I made in 2024 and certainly 2025). •Interestingly, the Federal Reserve Board’s industrial production data for battery manufacturing aren’t yet picking up this surge (https://lnkd.in/g3DjPFsP). The discrepancy may stem form most the FRB metric’s weight being pulled from, “Units, shipments, automotive replacement batteries, with model-based inventory adjustment; Battery Council International, FRB,” for storage batteries (NAICS 335911) and production worker hours for primary battery manufacturing (NAICS 335912) (see https://lnkd.in/gn4sFNn). This is an instance where I put more weight on Census Bureau data, as what they are picking up seems to better track the reality of EVs. Implication: if someone were to ask me what sector of manufacturing I am most bullish on in the USA, my answer would be battery manufacturing. I expect these data will become an increasingly important economic indicator over the coming years. #supplychain #supplychainmanagement #manufacturing #shipsandshipping #freight #trucking

🤔 Is it charging power, mileage or climate - as the BIGGEST driver of EV battery ageing?... Using aggregated telematics data from 22,700 EVs across 21 OEM models - making this one of the most comprehensive EV battery studies to date - Geotab’s data and telematics specialists uncovered several eye-opening insights:- 🔋🪫 Average battery degradation has stabilised at 2.3% per year - reinforcing that modern EV batteries are built to last beyond typical ownership and fleet replacement cycles. 🔋🪫 The data also shows charging power has overtaken mileage and climate as the single biggest operational factor.   🔋🪫 Vehicles relying heavily on DC fast charging above 100 kW degrade at up to 3.0% per year; those using mainly AC or lower-power charging average closer to 1.5% 🔋🪫 High utilisation does increase degradation slightly, but the trade-off is improved uptime, ROI and total cost per mile - particularly for fleets. 🔋🪫 Regularly using the full battery range has little impact on degradation, unless vehicles spend over 80% of their time at very high or very low charge levels. “EV battery health remains strong, even as vehicles are charged faster and deployed more intensively. Our latest data shows that batteries are still lasting well beyond the replacement cycles most fleets plan for. What has changed is that charging behaviour now plays a much bigger role in how quickly batteries age, giving operators an opportunity to manage long-term risk through smart charging strategies.” Charlotte Argue, Senior Manager, Sustainable Mobility at Geotab. As a single EV user or running an EV fleet, I'd say it's well worth looking through this battery study to understand the apparent characteristics of battery behaviour...just as the more widely known characteristics of engines and gearboxes are worth knowing in order to maximise longevity! ...you'll also get the answers to these FAQ's:- 1. What is the expected long-term performance and lifespan of EV batteries? 2. Has the EV battery degradation rate changed since the last Geotab study? 3. How is battery health measured and tracked over time? 4. How can fleet managers optimise charging practices to maintain EV battery health? #electricvehicles #batteries #automotive #charginginfrastructure

“The bear market for metals is one reason battery prices are forecast to decline. The other is that battery innovation is still ongoing, Bhandari says. Manufacturers are finding ways to simplify the manufacturing of batteries (through structure-related innovations that allow better, simpler packaging), and to use materials, like silicon, that may reduce charging time and increase energy density. Major innovations like solid-state batteries (as opposed to using liquid electrolyte as in batteries today) could, in the coming years, be a game-changer for the industry, as solid-state batteries are expected to allow carmakers to pack in even more energy, for the same amount of weight, than a conventional battery. “We’ve achieved quite a lot in terms of innovations,” Bhandari says. “For EVs to have a broad-based, economic-driven adoption, we need further step ups — in particular, battery structure-related innovations, as well as commercialization of next-generation technology including solid-state batteries.” There are other factors supporting the industry as well. The US Inflation Reduction Act’s subsidies could bolster the sector in the domestic US market.”

What does real-world data show about 7+ year, 100,000+ mile EV batteries? Last week, I shared data comparing LFP and NCA battery degradation in Tesla Model 3 Standard Range vehicles based on our pool of tests. I, first of all, thank all the people who interacted in the discussion, sharing their experiences and technical points of view as well. Then I thought it was worth sharing something related to older EVs. So I pulled the last 10 test results our customers did on Tesla Model S 75D vehicles from 2016-2018. At least 100,000 miles. 7+ years old. All using NCA chemistry with Panasonic 18650 cells. These vehicles are showing battery health between 82% and 88%, with an average mileage of 114,000 miles. That's after 7-9 years on the road and well over 100k miles of use. For context, Tesla's battery warranty guarantees 70% capacity retention at 8 years or 150,000 miles for the Model S. These vehicles are comfortably exceeding that threshold. What stands out is the consistency. There's no dramatic drop-off, no sudden degradation cliff. Just steady, predictable capacity retention even with significant age and mileage. This has real implications in the used EV market. 1. For accurate residual value estimation: Knowing these are the reference battery health values for a 2016-2018 Model S 75D with 100k+ miles, helps avoid both overvaluing and undervaluing inventory. 2. For customer confidence: Being able to show solid battery health data on a 7+ year old vehicle builds trust in the transaction. And with these strong results, these vehicles all qualify for our lifetime battery extended warranty. 3. For matching the right car to the right buyer: With this data available, it's easier to match these cars with buyers who don't need maximum range, but want a healthy Model S for a fraction of the price. What do you think about these results?

🔋 China initiates a bold endeavor to revolutionize the electric vehicle (EV) market by forming a consortium, CASIP (中国全固态电池产学研协同创新平台), comprising government, academia, and industry leaders like CATL and BYD. 🚗 The goal is to establish a solid-state battery supply chain by 2030, leveraging advanced technologies including artificial intelligence. 🤝 Major battery manufacturers, representing six of the top ten global automotive battery makers, unite for this national effort, setting aside rivalries to contribute to innovation: CATL, BYD subsidiary FinDreams Battery, CALB, EVE Energy and Gotion High-tech 🏢 Government support is integral, with ministries like Industry and Information Technology actively participating, highlighting China's determination to lead in automotive technology. ⚡ Solid-state batteries offer enhanced safety, higher energy density, and increased design flexibility, driving global competition from companies like Toyota, Nissan, Volkswagen, and BMW. 🌐 Despite China's dominance in current automotive battery technology, challenges exist in solid-state battery industrialization, with Japanese companies holding significant number patents in this field. 🔬 Technological advancements, particularly in AI-powered research, are expected to expedite progress, with breakthroughs anticipated by 2030. 💼 China's early adoption and industrialization of solid-state batteries could disrupt the global EV market, offering unprecedented opportunities for Chinese companies while challenging established players like Toyota.

🚘🔋 A leap forward in EV battery innovation! Samsung SDI, BMW Group, and Solid Power have announced a trilateral collaboration to validate and commercialize all-solid-state batteries (ASSBs) — a technology poised to redefine the future of electric mobility. Key highlights of this initiative: ⚡ Energy density of 500 Wh/kg — nearly double that of conventional lithium-ion batteries. 🛣️ 600 miles of driving range on a single charge. ⏱️ Ultra-fast charging: 10–80% in just 9 minutes, compared to ~45 minutes for today’s EVs. 🛡️ Superior safety: Solid electrolytes replace flammable liquid ones, making ASSBs non-combustible. ♻️ Longevity: Designed to last 20 years or ~2,000 cycles, equating to 1.2 million miles. 🧪 Materials innovation: Samsung’s design uses a silver-carbon layer as the anode and a nickel-manganese-cobalt cathode, leveraging silver’s conductivity and abundance. 🚀 Evaluation vehicles: BMW will integrate ASSB modules into next-gen prototypes by late 2026, marking a critical step toward commercialization. 📱 Beyond EVs: Samsung plans to debut ASSBs in smaller devices like the Galaxy Ring fitness tracker in 2026, before scaling to smartphones and laptops. While the exact pack size remains undisclosed, the promise of lighter, smaller, and safer batteries is clear. This collaboration also establishes a global value chain across materials, cells, and automotive applications — a model for industry-wide adoption. 💡 Why it matters: This partnership is not just about incremental gains; it’s about setting a new benchmark for EV performance, safety, and sustainability. With BMW’s engineering, Samsung’s manufacturing expertise, and Solid Power’s electrolyte technology, ASSBs are moving from lab prototypes to real-world vehicles. 👉 The road ahead: If successful, ASSBs could accelerate EV adoption globally, reduce charging anxiety, and open new applications across mobility and consumer electronics. Sources: https://lnkd.in/ggggyH2s https://lnkd.in/gf24nmWz https://lnkd.in/gGYijnWp