US battery technology firm Sion Power has developed a process that replaces conventional mechanical rolling with a vacuum deposition process that produces lithium anodes with a high level of control and efficiency, which has been a key barrier to lithium metal battery performance and scalability.
Traditional anode manufacturing relies on mechanical rolling, which limits the lithium thickness to 30-50 microns and requires the use of lubricants and additives during production. This process is restrictive and inefficient, creating cost and performance challenges for next-generation batteries, Sion explains.
Sion Power’s vacuum deposition method uses a roll-to-roll thermal evaporation process that deposits lithium directly onto copper foil at controlled speeds, allowing for the formation of ultra-thin and uniform films as thin as 2-3 microns. This flexibility allows for the precise tailoring of lithium thickness for various applications, reducing material usage and increasing cost efficiency.
The process also enables the use of engineered surface coatings that enhance lithium stability and performance. In customer testing, Sion Power’s 5-micron films delivered twice the cycle life of comparable competitor materials, according to the company.
The process is currently in use for producing anodes in Sion Power’s Licerion large-format battery cells manufactured in Tucson, Arizona.
“Our ability to deposit lithium in films from 2 to 50 microns with custom surface treatments positions us as the leader in lithium-metal anode technology,” said Tracy Kelley, President of Sion Power. “This innovation provides a true scalable path to high-performance batteries.”
Source: Sion Power
