The semi-solid-state battery has been achieved at the GWh-level already in China in 24H1, and also become the hottest issue to provide safer xEV usage and 1000 KM of driving range. This presentation will cover the Chinese semi-solid-state battery market, technologies, and manufacturing key issues to show the potentials and challenges.

The U.S. has made significant progress to establish a domestic battery manufacturing supply chain, but gaps remain. The Battery Advocacy for Technology and Transformation (BATT) Coalition is a voice for the U.S. battery materials manufacturers working to grow the upstream materials supply from extraction, synthesis, processing, and recycling. BATT’s mission is to advocate for legislative and federal policy that will promote market incentives and trade policies to support industry growth.

DSC and ARC were common methods to study Li-ion thermal runaway caused by Internal Shorts, which serious mismatch the time scale (<25mS) and heating area (Spot, 2 mm2) of battery internal shorts. The DSC (1998) and ARC (2003) created many theories on battery thermal runaway. Here, we are going to analyze various internal shorts supported by various giant battery producers (DATA) and analyze these shorts (via IEEE) and use laser (ms and 2mm2, SAFT) to mimic the internal short of the batteries to understand the thermal runaway caused by internal shorts. Through short Resistance study, Thermal propagation observation, Explosive GAS analysis, the Li-ion fire and explosion Mechanism will be presented, and the real solutions will be provided to reduce or eliminate Li-ion battery thermal runaway. The conclusions of this study, such as using ceramic coated separator (active approach), direct Cu/Al shorting (passive approach), etc. have been (extremely) broadly used in Li-ion industry today. The fire and explosion rate has been improved by 5 orders of magnitude. Now, all 3C and all NMC EDV and 70% LFP EDV are using the methods result from these improving methods.

To efficiently produce high-quality electrodes, it is crucial to control the microstructure of the battery slurry, rather than focusing solely on composition. However, we do not understand the stress and the signs that the slurry experiences and expresses during the process. We have developed an all-in-one solution called SlurryXpert that precisely analyzes data signals through machine learning and detects the characteristics of the slurry to distinguish the structural differences.

Highly efficient dissolvers, bead mills and basket mills are designed for the challenges of battery slurry development. In this presentation we’ll review the milling and dispersing requirements, process, and best practices. In addition, we will cover dispersing and milling equipment used to develop battery slurries as well as anode and cathode slurry development using proper mixing and dispersing equipment and battery slurry preparation and processing measurement for successful upscaling. High-performance dispersing and milling equipment is required for optimum performance of battery slurries.

The global acceleration towards sustainable energy has driven the need for low-cost, de-carbonized battery manufacturing processes with differentiating product performances. AM Batteries unique dry electrode manufacturing technology aims to deliver on these critical challenges and elevate battery production and performance globally. Our liquid-free battery electrode manufacturing process entails 3 key steps: dry mixing, dry deposition, and mechanical compression. In this symposium, we will highlight our achievements and manufacturing advantages over other electrode process options.

Plasma printing is an advanced method for fabricating battery electrodes, offering flexibility for multi-layer processes without needing binders or toxic solvents. This innovative technique enables the combination of cutting-edge materials, making it especially valuable for high-silicon anodes, sodium-ion batteries, and solid-state batteries. Plasma printing enhances performance, durability, and functionality by eliminating toxic chemicals and allowing precise, scalable integration of multiple materials. The process reduces environmental impact while improving the efficiency of energy storage devices. This approach opens new possibilities for advancing battery technologies, paving the way for cleaner, more efficient, and sustainable energy solutions.

We have developed a cutting-edge, high-speed atmospheric spatial ALD technology that significantly enhances lithium-ion and next-generation battery safety and performance. By applying Al2O3 coatings to separators and anodes, this technology not only improves fire prevention and thermal stability but also inhibits dendrite growth on anodes, a key cause of battery failure. Our findings demonstrate how this innovation enhances battery durability and reliability, addressing critical industry challenges.