Titomic announces breakthrough in lithium‍-‍ion electrode manufacturing

Australian cold spray additive manufacturing company Titomic Limited has announced a major advancement in the application of its Titomic Kinetic Fusion (TKF) technology for lithium-ion battery electrode manufacturing.

Traditionally, lithium-ion battery electrodes are manufactured using slurry-based processes that require multiple steps, including mixing, coating, drying and calendaring. To overcome the limitations of this conventional approach, Rensselaer Polytechnic Institute (RPI), with support from the National Science Foundation (NSF) Energy Storage Engine in Upstate New York Program, has partnered with Titomic. RPI is partnering with Titomic in advancing cold spray–based dry-coating technologies aimed at enabling next-generation battery electrode manufacturing. Titomic’s cold-spray approach, TKF, eliminates the energy- and time-intensive stages by directly depositing electrode powders onto aluminium or copper foils. This innovation can be seamlessly integrated into existing roll-to-roll production lines or adapted for 3D-printed electrodes with customised geometries and compositions.

The company’s technical program, in collaboration with Rensselaer Polytechnic Institute, is structured in four phases:

• Phase 1 — Material feasibility: Trials of candidate anode and cathode powders (such as silicon, LTO, LMO and LFP) deposited onto foil substrates, with detailed micro- and macro-level characterisation to determine spray parameters.
• Phase 2 — Down-selection and demonstrator: Development of electrode demonstrators meeting industry requirements, including electrochemical testing for performance verification.
• Phase 3 — Pilot TKF CS station: Deployment of a pilot-scale system integrated with a customer’s LIB roll-to-roll manufacturing line.
• Phase 4: Detailed scalability and cost analysis to evaluate the transition from laboratory demonstrations to large-scale industry applications.
   

Titomic says this approach addresses critical industry needs for more sustainable, efficient and scalable electrode manufacturing. Beyond conventional graphite anodes, Titomic’s process enables advanced silicon–copper composite electrodes, which offer ultra-high theoretical capacity, and supports the development of all dry-coated (solvent-and binder-free) lithium-ion batteries.

“This deposition breakthrough represents a pivotal moment in our expansion into the clean energy sector,” said Jim Simpson, Titomic CEO and Managing Director. “By applying our proven TKF cold spray technology to battery electrode manufacturing, Titomic is helping to overcome longstanding efficiency and sustainability challenges in lithium-ion battery production. This development not only benefits our customers but also supports the global transition to renewable energy and electrification.”

“By directly depositing functional electrode materials via cold spray technology — without the need for binders, solvents or drying steps — we are addressing critical inefficiencies in traditional slurry-based LIB production,” said the researchers from Rensselaer Polytechnic Institute. “Titomic’s dedicated cold spray systems enable direct and high-throughput deposition of lithium-ion battery electrodes, helping to accelerate the transition toward renewable energy adoption and widespread electrification.”

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