Rensselaer Polytechnic Institute (RPI) is working with Titomic to advance its Titomic Kinetic Fusion technology for lithium-ion battery (LIB) electrode manufacturing.
With support from the National Science Foundation (NSF) Energy Storage Engine in Upstate New York Program, the two organisations are developing cold spray–based dry-coating technologies.
Titomic’s TKF cold-spray approach is said to eliminate the energy and time-intensive stages by directly depositing electrode powders onto aluminium or copper foils. This, the partners say, can be seamlessly integrated into existing roll-to-roll production lines or adapted for 3D printed electrodes with customised geometries and compositions.
A technical programme structured in four phases will seek to develop the solution in the lab and chart a pathway into industry. First, a material feasibility effort will conduct 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. The down-selection & demonstrator phase will then develop electrode demonstrators that can meet industry requirements before a pilot-scale system is deployed with a customer's LIB roll-to-roll manufacturing line. Finally, a detailed scalability and cost analysis will be carried out to evaluate the transition from laboratory demonstrations to large-scale industry applications.
Through this programme, the partners hope to address critical industry needs for more sustainable, efficient, and scalable electrode manufacturing.
“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 long-standing efficiency and sustainability challenges in lithium-ion 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,” added Prof. Semih Akin and Prof. Nikhil Koratkar, NSF project PIs from Rensselaer Polytechnic Institute. “Titomic’s dedicated cold spray systems enable direct and high-throughput deposition of LIB electrodes, helping to accelerate the transition toward renewable energy adoption and widespread electrification.”
