High Energy Density Batteries Research Articles

Novel electriferous charge-mosaic S(TMC@Lys-Li) separator towards efficient Li+ fast-transfer for high-energy density and long-duration lithium-sulfur batteries

Lithium-sulfur (Li-S) batteries with attractive capacity give remarkable potential for prospective high-capacity application scenarios but suffer a fatal flaw of short cyclability before large-scale commercialization especially owing to polysulfide (Li2Sn) transmembrane shuttling. To efficiently restrain chronic Li2Sn shuttle and expedite Li+ transfer, herein, a novel electriferous charge-mosaic S(TMC@Lys-Li) separator preparation approach is recommended. Interfacial polymerizations of lithiated lysine and trimesoyl chloride establish an electriferous charge-mosaic polyamide functional layer. Substituted Li within the charge-mosaic layer offers transition or replacement sites for smoothing Li+ migrations, which constructs efficient Li+ fast-transfer private channels and accelerates the Li+ transfer rate to 9.4 times. Negatively charged polyamide skeleton synchronously heightens Li2Sn rejections by combining Donnan and steric effects. S(TMC@Lys-Li) replenishes Li for homogenizing Li nucleation and growth, endowing stable plating/stripping behaviors over 250 cycles for Li-Cu batteries. Assembled Li-S cells thus exhibit excellent specific capacity and cyclability at multiple application scenarios such as long periods, high areal capacity, and fast charge, holding 78.1% retention after 500 cycles at 1 C. The superior thermal stability and self-discharge of S(TMC@Lys-Li) dramatically strengthen battery thermal runaway resistance even at 155 ℃, which ensures security for Li-S battery high-power and high-temperature operations. Above alluring features enable charge-mosaic separators to be potentially adopted in practical Li-S batteries demanding strict security, high-capacity density, and fast charge technology.

Microporous Polyethylene and Cellulose Composite Separators for Reversible Lithium Electrode in Lithium Rechargeable Batteries

AbstractThe lithium metal anode is the best candidate for high energy density batteries because of its high specific capacity and low negative potential. Rechargeable lithium metal batteries (RLMB) have not yet been commercialized. The key factors that limit the practical use of RLMB are the formation and growth of lithium dendrites during the lithium deposition process and the reaction of the lithium anode with the organic solvent of the electrolyte, quantified by the Columbic efficiency (CE). To suppress the lithium dendrite formation and to improve CE, many approaches such as the formation of a protective layer on the lithium electrode and the use of additives to the electrolyte have been proposed. In this study, the effect of a thin cellulose film to improve CE of lithium deposition and stripping on the lithium electrode was examined. The cycle performance of a Li/Li symmetrical cell with a cellulose and polyethylene composite separator was examined for a carbonate electrolyte and an ether electrolyte. The improvements of CE were observed for both electrolytes with the cellulose film separator. The improvement could be explained by the good wettability of the cellulose film separator with the electrolyte.

Design Lithium Exchanged Zeolite Based Multifunctional Electrode Additive for Ultra‐High Loading Electrode Toward High Energy Density Lithium Metal Battery

AbstractThe practicalization of a high energy density battery requires the electrode to achieve decent performance under ultra‐high active material loading. However, as the electrode thickness increases, there is a notable restriction in ionic transport in the electrodes, limiting the diffusion kinetics of Li+ and the utilization rate of active substances. In this study, lithium‐ion‐exchanged zeolite X (Li‐X zeolite) is synthesized via Li+ exchange strategy to enhance Li+ diffusion kinetics. When incorporated Li–X zeolite into the ultra‐high loading cathodes, it possesses i) high electron conductivity with a uniform network by reducing tortuosity, ii) decent ion conductivity attributes to modulated Li+ diffusivity of Li‐X and iii) high elasticity to prevent particle‐level cracking and electrode‐level disintegration. Moreover, Li–X zeolite at the solid/liquid interface facilitates the formation of a stable cathode electrolyte interface, which effectively suppresses side reactions and mitigates the dissolution of transition cations. Therefore, an ultra‐high loading (66 mg cm−2) cathode is fabricated via dry electrode technology, demonstrating a remarkable areal capacity of 12.7 mAh cm−2 and a high energy density of 464 Wh kg−1 in a lithium metal battery. The well‐designed electrode structure with multifunctional Li–X zeolite as an additive in thick cathodes holds promise to enhance the battery's rate capability, cycling stability, and overall energy density.

Developing a lithiophilic, solvent-phobic dual-functionality film for dendrite-free Li metal anodes

Li metal anodes (LMAs) are promising candidate for advanced batteries that encounters significant challenges, including electrolyte corrosion and uneven deposition. These issues not only reduce battery lifespan but also pose safety risks due to the uncontrolled growth of dendrites. Herein, we introduce a lithiophilic, solvent-phobic dual-functionality film (LSDF) designed to tackle these problems. The LSDF features an inner layer of polyethylene oxide directly applied to the LMAs and an outer layer of poly(vinylidene fluoride-co-hexafluoropropylene) facing the electrolyte. Both layers contain N-ethyl-N-methylpyrrolidinium bis(trifluoromethanesulfonyl)imide, which enhances the rapid transport of Li ions. The inner layer promotes high interfacial stability, while the outer layer offers solvent resistance and Li affinity, thereby inhibiting dendrite growth and reducing side reactions. Consequently, Li||Li symmetric cells achieve stable cycling for 1650 h with a minimal overpotential of 15 mV at 3 mAh cm−2 and 3 mA cm−2. Additionally, full cells paired with LiFePO4 cathodes maintain 85 % capacity retention over 500 cycles at 1 C and demonstrate excellent rate capability. This study presents a new approach to modulate the interface of LMAs, significantly enhancing its stability for high-energy–density battery applications.

Aging mechanism of Ni-rich cathode-based lithium-ion batteries: Focusing on upper cut-off voltages

Ni-rich cathode-based lithium-ion batteries are subject to certain limitations in electric vehicle applications due to their cycle life. Therefore, this study aims to investigate the aging mechanism of Ni-rich cathode-based lithium-ion batteries with different upper cut-off voltages, providing ideas for improving their cycle life. The change in the cathode lattice during the charging and discharging process obtained by in-situ XRD shows that the H2-H3 phase transition exacerbates the battery capacity degradation. In addition, the capacity degradation caused by lattice strain induced by the rapid release of anisotropic stress accumulation (ASA) in the H2 region cannot be ignored as well. After lowering the upper cut-off voltage, the surplus lithium in the cathode plays a pivotal role in avoiding the above rapid battery degradation, driven by the advantages of its ability to stabilize lattice structure and reduce the degree of Li/Ni cation mixing. Meanwhile, the low upper cut-off voltage effectively avoids side reactions such as electrolyte decomposition and transition metal dissolution. The above results would contribute to slowing down battery degradation, which would provide strong support for the design of high energy density and long-life lithium-ion batteries.

Engineering texture and twins of Cu foils preparing by pulse electrodeposition and their properties

The controllable microstructure and the overall performance improvement of electrodeposited nano twinned Cu (nt-Cu) foil are crucial for the sustainable development of high energy density batteries and microelectronics technology. Although pulse electrodeposition (PED) and additives have been widely used in controlling nt-Cu foil, there is still a lack of research on the controllable microstructure of nt-Cu foil and its microstructure depended properties. In this study, nt-Cu foils with different orientations were prepared by adjusting the Toff time and additives during the PED process. The effects of these parameters on the microstructure and comprehensive properties of the nt-Cu foil were studied. The Toff time and polyethylene glycol (PEG)-3-mercapto-1-propanesulfonate sodium salt (MPS)-(chloride ions)Cl− (PEG-MPS-Cl−) additive changed the kinetic parameters of the electrochemical reaction and ultimately affected the reduction rate of Cu2+ and the overpotential of the deposition process. This modulation effectively regulated the nucleation and growth behavior of Cu atoms, thereby reducing the surface roughness of the nt-Cu foil, refining the grains, and forming nano-twins with different orientations. Due to the combined strengthening effect of grain refinement, dislocation, and texture orientation, (111) oriented nt-Cu foil demonstrated remarkable mechanical and frictional wear properties, whereas (220) oriented nt-Cu foil exhibited superior conductivity and corrosion resistance. These findings may offer promising prospects for the controllable design of engineering textures and nano-twin structures of high-performance nt-Cu foil by electrodeposition.

Unit prediction horizon [formula omitted] based model predictive control for the fuel cell based plug-in hybrid electric vehicle with rule-based energy management system

Plug-in hybrid electric vehicles (PHEVs) provide a good alternative in achieving better performance and in the reduction of harmful gas emissions. The hybrid energy storage system (HESS) and the integrated charging unit constitute the PHEV under consideration. To meet the load demands, the proposed HESS is a coupled system comprising a fuel cell, high energy density battery, and high-power density super-capacitor. On-board charging involves the utilization of a DC–DC buck converter and an uncontrolled rectifier and two buck-boost converters are utilized to facilitate a smooth transfer of energy. A rule-based supervisory controller has been implemented for different load conditions which takes into account the state of charge of energy sources and also the total power inflow of the power sources. A model predictive control (MPC) technique is implemented to ensure that PHEVs function smoothly in terms of regulation of DC bus voltage and tracking of current. Unit prediction horizon i.e. only one step ahead looking into the future is considered for the MPC to make it computationally less expensive. MPC is designed in such a way that its performance is close to our favorite linear controller which in our case is the H∞ controller. The inverse optimal control technique is used for determining the weight matrices of the cost function. The proposed controller has been simulated using MATLAB. Also, the performance comparison is made between the designed MPC and the non-linear control approach i.e. integral sliding mode control and integral backstepping-based control to show that it achieves comparable or superior performance to the non-linear controller. The real-time performance of H∞ based MPC is verified using controller hardware in the loop experimental setup.

Facile Synthesis of flexible free-standing electrode for high energy density batteries by using PTMSP as binder

As a crucial component of the electrode, the binder greatly impacts battery performance. Herein, we report a novel binder, poly[1-(trimethylsilyl)-1-propyne] (PTMSP), which enables the construction of flexible free-standing electrodes for high performance lithium-ion batteries. The free-standing electrodes based on the PTMSP binder demonstrate remarkable cycling performance in various electrode materials, including LFP, S, and LTO, demonstrating significant potential for market application.

Fully Conjugated Covalent Triazine Framework Integrating Hexaazatrinaphthylene Unit as Anode Material for High-Performance Hybrid Lithium-Ion Capacitors.

As a high-performance energy storage device consisting of a battery-type anode and a capacitor-type cathode, hybrid lithium-ion capacitors (HLICs) combine the advantages of high energy density of batteries and high power density of capacitors. However, the imbalance in electrochemical kinetics between the battery-type anode and the capacitor-type cathode hinders the further development of HLICs. Fully conjugated covalent organic frameworks have great potential as electrode materials for HLICs due to the designability of their structure. Herein, a fully conjugated covalent triazine framework (PT-CTF) integrating the hexaazatrinaphthylene unit was constructed, which provides abundant active sites (C═N and C═C groups) as the pseudocapacitive anode material for HLICs. And the connection of the triazine unit of PT-CTF improves the molecular conjugate degree, facilitating the transport of electrons. The fabricated PT-CTF||AC HLICs exhibit a high energy density (164.9 Wh kg-1 at 100 mA g-1), large power density (13.1 kW kg-1 at 4 A g-1), and excellent cycling capability (72% after 10 000 cycles at 2 A g-1).

High gravimetric energy density lead acid battery with titanium-based negative grids employing expanded mesh sandwich structure

Addressing the low gravimetric energy density issue caused by the heavy grid mass and poor active material utilization, a titanium-based, sandwich-structured expanded mesh grid (Ti/Cu/Pb) for lead-acid battery negative electrode is introduced. Titanium was chosen for its advantageous properties such as low density, high mechanical strength, and good electrical conductivity, which reduces the electrode mass and enhances battery gravimetric energy density. However, titanium's use in battery negative grids is limited due to its passivation in sulfuric acid and poor adhesion to the active material. To overcome these drawbacks, a copper layer is added to prevent passivation, and a lead layer is applied to improve the adhesion between the titanium matrix and the active material. This innovative Ti/Cu/Pb negative grid reduces electrode mass and increases current density, boosting active material utilization. Electrode with Ti/Cu/Pb negative grid achieves an gravimetric energy density of up to 163.5 Wh/kg, a 26 % increase over conventional lead-alloy electrode. With Ti/Cu/Pb negative grid, battery cycle life extends to 339 cycles under a 0.5C 100 % depth of discharge, marking a significant advance over existing lightweight negative grid batteries. This research not only demonstrates a significant step in lead-acid battery enhancement but also proposes a methodological approach for future high gravimetric energy density battery design.

The numerical and experimental investigation of the transient behaviours of a lithium-ion pouch battery cell under dynamic conditions

In this paper, the transient model of a high energy density Lithium-ion pouch battery cell is developed under dynamic conditions. The battery cell has a capacity of 73 Ah and volumetric energy density of 642 Wh L−1. This is one of the few studies included the electro-thermal behaviour of high energy density battery under transient conditions by using second ordered model. The transient model indicated that the state of charge (SOC) decreased by 7 % at the end of the WLTP driving cycle and this value is good agreement with the experimental data. Moreover, the developed model provides an accurate prediction of the terminal voltage with a R2 value of 0.99 and a maximum relative error of 2.0 %. Furthermore, the proposed model predicts the electro-thermal characteristics more precisely and the heat generation rate and the entropic term can also be determined without using measurement device. The calculated total heat emitted from battery is about 6W at 1 C-rate for constant current and the heat generation rate is a peak value of ±1.75 105 Wm−3 under dynamic conditions. By using the estimated heat generation rate, more effective cold plates will be designed for thermal management of high energy density battery cells.

Design of alveolar biomimetic enhanced heat transfer structure for cylindrical lithium battery pack

Aiming to address the issue of thermal runaway in high energy density batteries during high charge and discharge rates, a heat management system for an alveolar-like honeycomb liquid-cooled power battery was designed. This system is inspired by the bionic concept of cell cooling in biological tissues, with cylindrical batteries serving as cells and cooling channels resembling blood vessels. The cooling system for a battery pack consisting of 24 cylindrical cells was designed and implemented. Numerical simulations were conducted to optimize and study the effects of inlet diameter, branch angle, flow rate, and spiral baffle on coolant flow uniformity and temperature distribution within the battery pack. The results indicate that as the inlet diameter of the fractal channel increases from 2 mm to 20 mm, the coolant flow uniformity improves and the pressure drop decreases. However, the influence of inlet diameter diminishes after reaching a certain limit. When the inlet diameter increases from 10 mm to 20 mm, the relative standard deviation of the velocity at the branch outlet decreases only slightly, from 0.9 % to 0.8 %. Increasing the branch angle from 30° to 75° leads to an increase in the relative standard deviation of velocity, from 0.79 % to 1.24 %. Incorporating a spiral baffle into the internal flow channel of honeycomb cooling significantly enhances temperature uniformity within the battery pack while reducing maximum temperature levels considerably. Furthermore, a smaller pitch for the spiral baffle yields better cooling performance for the immersed liquid cooling thermal management system. After optimization, the maximum temperature difference is only 1.27 °C across the surface of the battery pack, achieving a remarkable temperature uniformity level of just 0.11 %.

Microscopic insights into effects of sulfolane additive on Li–S battery electrolyte

Lithium–sulfur (Li–S) batteries, which have a high theoretical capacity and can be prepared using low-cost activation materials, are a promising alternative for realizing high-energy-density battery systems. However, the stability of the electrolyte and the shuttle effect caused by dissolved lithium polysulfides in the electrolyte prevent their practical application. Due to its non-flammability and high oxidation stability, sulfolane shows good promise for improving the oxidation stability and weakening the shuttle effect of Li–S electrolytes. In this work, the effects of a sulfolane additive on a Li–S battery electrolyte were revealed by density functional theory calculations and molecular dynamics simulations. The molecular orbitals, thermodynamics, and dynamics of the oxidation reaction were analyzed from the electron level. The addition of sulfolane lowers the HOMO energy level and the configuration energy difference, which leads to improved oxidation stability. Furthermore, sulfolane shows affinity to the S atoms close to Li, which correspond to low-order polysulfides. This affinity is confirmed by binding energy data and indicates that the addition of sulfolane inhibits the diffusion of Li2S4, Li2S6 and Li2S8. This work provides an analysis of the effects of sulfolane as an additive from the electron and molecular levels, which will promote a better understanding of Li–S battery systems and enable the design of improved electrolytes.

Reversible Li-ion trade-off in ultrathick sulfur cathodes for practical lean Li–S batteries

The use of low electrolyte volume is beneficial to improve energy density but severely limits access over obscured sulfur, along with sluggish ion kinetics and aggravated polarization, as the ion imbalance across the multicomponent interface of thick sulfur cathodes at a lean electrolyte viciously dominates the sulfur electrokinetics. Herein, we demonstrate that an ion imbalance at the interfaces of a thick electrode with a lean electrolyte can be compensated by the ion trade-off strategy utilizing a cationic ion conductive active binder. It ensures sustained lithium-ion donation/release over the vicinity of slow electrolyte percolation to realize an ion-enriched sulfur–binder–electrolyte interface. The in-situ evolved ionic interface essentially activates the inaccessible sulfur, bringing about additional capacity and low ion and charge transfer resistances. The active binder adopts sulfur cathodes housing 8.1 mg cm–2 with an E/S ratio of 6 µL mg–1 electrochemically utilized 60.89 % sulfur, corresponding to a 1020 mAh g–1 capacity. The lean Li–S pouch cell delivers an energy density of 324 Wh kg–1, demonstrating the efficacy of ion trade-off to ease the interfacial barrier. This study would open up a new paradigm in potentially designing thick electrodes for multiple high energy density batteries.

Electrolyte with weakly coordinating solvents for high-performance FeS2 cathode

As the “blood” of batteries, the electrolyte is generally expected to be designed reasonably to meet the demands of stable energy storage in high energy density batteries. This study introduces a rational design for localized high-concentration electrolytes (LHCEs) by incorporating the weakly coordinating diluent 1, 1, 2, 2-tetrafluoro-1-methoxyethane (TFM) to modulate the solvation of Li+ alongside the anion and solvent 1, 2-diethoxyethane (DEE). The resulting LiFSI-DEE/2TFM electrolyte (1 M LiFSI in DEE/TFM at a ratio of 1:2, volume) demonstrates a significant efficacy in suppressing the dissolution of lithium polysulfides (LiPSs) while maintaining a good ionic conductivity. Moreover, this electrolyte facilitates the formation of a stable cathode-electrolyte interphase (CEI) and promotes uniform plating/stripping of Li+ at the lithium anode. Consequently, based on this electrolyte, the Li/FeS2 cells exhibit an exceptional specific capacity and a good cycling stability from room temperature to −20°C. Notably, even at −20°C, over 80 % of the room-temperature specific capacity (692.7 mAh g−1@150th) is retained for the cell using LiFSI-DEE/2TFM, showing its robust performance in challenging environments. Furthermore, the Li/FeS2 cell also demonstrates an outstanding durability at high current density (≥ 2 C) under room temperature.

A novel hybrid sodium ion capacitor based on Na [Ni0.60Mn0.35Co0.05] O2 battery type cathode and presodiated D-Ti3C2Tx pseudocapacitive anode

The combination of the high-power density of supercapacitors and the high energy density of batteries makes hybrid sodium-ion capacitors (HSICs) a promising device. HSICs can provide better performance characteristics by harnessing both ion adsorption/desorption in the capacitor-type electrode and sodium-ion intercalation in the battery-type electrode. Here, the synthesis of MXene (Ti3C2Tx), a two-dimensional (2D) carbide and nitride is reported. Delaminated MXene (D-Ti3C2Tx) is a promising candidate for anode material in HSIC due to its large surface area (∼ 42 m2/g) and good electronic conductivity. Electrochemical study indicates that D-Ti3C2Tx anode exhibits a high discharge capacity of ∼213 mAh/g at a current rate of 20 mA/g. Further the presodiated D-Ti3C2Tx anode is paired with Na [Ni0.60Mn0.35Co0.05] O2 (P2-NMC) cathode to obtain the configuration of HSIC. The HSIC exhibits good specific capacitance of ∼187 F/g and specific discharge capacity of ∼110 mAh/g at a current density of 10 mA/g, according to the electrochemical analysis. A notable improvement in specific energy density (∼ 256 Wh/kg) and specific power density (∼579 W/kg) is also demonstrated by the HSIC. With P2-NMC being used as the cathode material rather than traditional activated carbon, there has been a rise in specific energy density.

Pristine NASICON Electrolyte: A High Ionic Conductivity and Enhanced Dendrite Resistance Through Zirconia (ZrO2) Impurity-free Solid-Electrolyte Design.

Sodium batteries are considered a promising candidate for large-scale grid storage at tropical climate zone, and solid-state sodium metal batteries have a strong proposition as high energy density battery. The main challenge is to develop ultra-pure solid-state ceramic electrolyte and compatible metal interface. Here, a scalable and energy-efficient synthesis strategy of sodium (Na) Super Ionic CONductor, Na1+xZr2SixP3-xO12(x = 2, NZSP) solid electrolyte, has been introduced with the complete removal of unreacted zirconium oxide (ZrO2) impurities. Additionally, the reaction mechanism for the formation of pure phase NZSP is reported for the first time. The NZSP prepared by utilizing the Zr precursor, i.e., tetragonal zirconium oxide (t-ZrO2) derived from the Zr(OH)4 gets quickly and completely consumed in the synthesis process leaving no unreacted monoclinic ZrO2 impurities. The synthesis process only needs a minimum stay of 4 h, which is three times less than the conventional synthesis method. The elimination of ZrO2 impurities results in a 2.5-fold reduction in grain boundary resistivity, showcasing a total ionic conductivity of 1.75 mS cm-1 at room temperature and a relative density of 98%. The prepared electrolyte demonstrates remarkable resistance to dendrite formation, as evidenced by a high critical current density value of 1.4mA cm-2.

Design of CTP liquid cooling battery pack and thermal Characterization experiments

Range has emerged as a significant barrier to the advancement of electric vehicles, necessitating the development of high-energy–density battery packs. However, the conventional battery integration method, CTM (Cell to Module), has a relatively low space utilization rate, which presents a challenge to the enhancement of vehicle range. Consequently, a novel battery pack integration method, CTP (Cell to Pack), has emerged as a potential solution. In order to enhance the integration degree and effective energy density of the battery pack, a CTP and a symmetric serpentine runner liquid cooling plate are proposed in this paper. A thermal model of a single cell was constructed, and the cooling performance of the battery pack under different discharge conditions was analyzed. The optimal inlet water temperature and coolant mass flow rate were then determined. The findings indicate that the battery pack devised in this study exhibits commendable cooling capabilities and is capable of satisfying the cooling requirements associated with a 2C discharge scenario. Furthermore, when the battery pack is operated under Chinese Light Vehicle Driving Conditions (CLTC), the inlet flow rate of 2 L/min has been observed to reduce the maximum temperature differential by 1.31 °C in comparison to a scenario without internal coolant circulation.

Chitosan-derived N-doped porous carbon with fiber network structure for advanced lithium‑sulfur batteries

The flexible design and construction of advanced carbon-based sulfur hosts contribute to the rapid redox and reaction kinetics of lithium polysulfides (LiPSs) in lithium‑sulfur batteries (LSBs), laying the foundation for the next generation of high-energy density energy storage devices. Herein, chitosan (CS)-derived porous N-doped carbon with fiber network structure was prepared by a simple freeze-drying method combined with sintering process. The effect of inorganic salt additives on the morphology of CS-derived carbon was investigated by SEM. The types and contents of N-doping were investigated through XPS analysis. The influence of morphology and N content on the performance of LSBs has been explored in detail through cycling and CV testing. In addition, the true active sites in the CS-derived carbon were determined by XPS and first principles calculations. As an active species, pyrrolic N exhibits superior adsorption energy and the most suitable degradation energy barrier for LiPSs. As the optimal electrode, the performance of LSBs under different electrolyte to sulfur (E/S) conditions was further investigated to explore the potential application of CS-KOH electrodes in high-energy density batteries. The results unveil that the influence of E/S on Li2S deposition is quite significant, with a limit of 5 μL mg−1. This work provides a new strategy for the preparation of high-performance advanced carbon-based materials with fiber network structures from polysaccharide biomass, and also promotes the application of CS in energy storage.

(Invited) Advanced Processing Science for Low-Cost, High Energy Density Batteries

This project at the DOE Battery Manufacturing R&D Facility (BMF) at Oak Ridge National Laboratory (ORNL) has built research successes on advanced battery processing science and engineering (PSnE), cost reduction, and cell energy and power density improvements. Our goal is to perform the processing science and engineering needed to reduce high-risk, high-payoff technologies to lower risk levels, such that the U.S. industry will consider their integration in future products.Electron beam curing is demonstrated as a promising method for high speed, low cost and environmentally friendly battery electrode manufacturing. This work reports transfer of this process to pilot scale equipment and evaluation of electrochemical performance in prototype 1.5 Ah pouch cells. Thick NMC composite electrodes with an areal loading of 25 mg cm−2 (∼4 mAh cm−2) are successfully cured at a line speed of 500 feet per minute. This work demonstrates that electron beam curing is a promising method for manufacturing thick battery electrodes at high speeds and low capital/operation cost.