Solid-State Battery Commercialisation
Pinpointing the cell chemistries, interface treatments, and production routes to deliver high-energy, durable, and cost-effective solid-state batteries for a 2028 SOP window.
Client
Automotive OEM
Objective
Achieve $80 kWh⁻¹ Pack Cost
Timeline
10-Week Sprint
Key Focus
Energy Density & Safety
The Challenge: Three Technical Barriers to Mass Production
Solid-state batteries promise a step-change in energy density and safety, but three major technical barriers still block their path to mass production and widespread EV adoption.
Dendrite Suppression
Metallic lithium can still pierce solid electrolytes during fast charging, causing dangerous short-circuits that negate the battery's intrinsic safety.
Brittle Interfaces
Ceramic electrolytes can crack or delaminate from the electrodes as they swell and shrink during cycling, degrading performance over time.
Scalable, Dry Manufacturing
Most solid electrolytes require moisture-free environments and high-temperature sintering, making affordable, roll-to-roll production a major unresolved challenge.
Key Outcomes: Five Lead Pathways to Commercialisation
After techno-economic modeling of 15 leading stacks, our analysis delivered five pilot-ready concepts with a clear roadmap to a 2028 start of production.
Sulfide Electrolyte + Li-metal Anode
Offers high conductivity (6 mS cm⁻¹) and dendrite resistance.
Al-doped LLZO Tape-Cast Sheet
Projects 380 Wh kg⁻¹ at the pack level with low-temperature sintering.
Hybrid Polymer-Ceramic Film
Enables roll-to-roll lamination in a low-humidity dry room.
Li₃N Interface Buffer
A coating that dramatically reduces resistance growth over 1,000 cycles.
Vapor-phase Densified Sulfide Stack
Achieved ≥92% pilot yield with an estimated cost of $85 kWh⁻¹ by 2029.
Strategic Impact
With a clear material and process shortlist, the OEM launched a joint-development agreement with a sulfide-electrolyte supplier and began designing a 2 MWh pilot line. Achieving mass-market solid-state packs by 2029 will raise vehicle range by ~30% while meeting stringent safety targets, strengthening the OEM’s leadership in next-generation EV technology.