In response to this challenge, a collaborative team of researchers from Pohang University of Science and Technology (POSTECH) and Chung-Ang University has made a groundbreaking advance in lithium-metal battery (LMB) technology. Led by Professor Soojin Park, Dr. Dong-Yeob Han, and Ms. Gayoung Lee at POSTECH, alongside Professor Janghyuk Moon and Mr. Seongsoo Park from Chung-Ang University, the team engineered a novel three-dimensional porous host structure that markedly enhances battery safety and lifespan. Their innovative strategy centers on circumventing the problematic dendrite formation in lithium metal batteries, a long-standing obstacle in the path to commercialization due to catastrophic failure risks.

Lithium metal batteries hold considerable promise over current lithium-ion technologies due to their ability to store energy at much higher densities. These batteries could realistically extend the driving range of electric vehicles by a significant margin. However, uneven lithium deposition during electrochemical cycling results in the growth of needle-like metallic dendrites. These dendrites jeopardize battery reliability by piercing the separator, leading to internal short circuits and, in severe cases, battery fires or explosions. Stabilizing lithium metal anodes has been a formidable technical hurdle, requiring innovative solutions that do not compromise battery performance or increase production complexity.

The research team’s breakthrough lies in their use of a porous host with low tortuosity channels—a design that optimizes lithium-ion transport and deposition pathways within the battery. Through clever engineering that mimics a multi-level parking structure, the host framework encourages uniform lithium plating from the bottom upwards, minimizing dendrite formation. The premise is that just as efficient design facilitates orderly car parking, an inviting path with minimal resistance ensures lithium ions settle evenly across the host’s internal surfaces. This architectural control over lithium metal growth transforms the battery’s internal dynamics, mitigating one of the technology’s most dangerous failure modes.

Fabricating this sophisticated porous host involved a nonsolvent-induced phase separation (NIPS) method. The researchers leveraged a polymer matrix infused with conductive carbon nanotubes and silver nanoparticles, which together enhanced the overall electrical conductivity of the host structure. Further adding an additional silver layer atop a copper substrate acted as a lithium nucleation site at the base. This gradient of lithiophilic properties steers lithium ions to deposit evenly from the bottom up. The resulting assembly promotes a fully suppressed dendritic growth while enhancing the electrode’s mechanical stability during cycling.

Performance testing of these batteries revealed transformative improvements in energy density, achieving values as high as 398.1 Wh/kg by weight and 1,516.8 Wh/L by volume. These figures far eclipse the typical energy densities achieved in conventional lithium-ion batteries, which hover around 250 Wh/kg and 650 Wh/L, respectively. Such enhancements suggest practical EV applications could see their driving ranges extended drastically. For instance, a vehicle currently capable of about 400 kilometers per charge could potentially achieve 650 to 700 kilometers with batteries fabricated using this technology, revolutionizing the electric vehicle landscape.

Crucially, the team demonstrated that their porous host design maintains outstanding stability even under commercial-scale conditions. These trials included the use of realistic cathode materials such as nickel-cobalt-manganese (NCM811) and lithium iron phosphate (LFP), thin lithium anodes, and low electrolyte volumes, which more closely resemble practical battery configurations rather than idealized laboratory setups. The batteries consistently resisted short circuits and capacity degradation, underscoring the practicality of this approach for real-world energy applications.

Professor Soojin Park emphasized that this research represents a fundamental shift in how lithium metal battery electrodes can be designed by simultaneously controlling ion transport pathways and lithium growth dynamics within the battery structure. Importantly, the manufacturing process eschews complex or high-cost techniques, thereby streamlining the route towards commercial viability. By controlling both the physical paths lithium ions traverse and their chemical interaction directions, this work promises to overcome one of the most challenging aspects of high-energy-density battery development.

Adding to these insights, Professor Janghyuk Moon highlighted the process’s scalability and industrial relevance. The ability to seamlessly integrate microstructural regulation with chemical gradient design through a relatively simple fabrication method opens pathways for mass production, a critical factor for the future of energy storage technologies. The team’s approach exemplifies how nuanced control at multiple scales—from nanoscale materials to macroscopic battery components—can collectively enhance performance metrics and safety profiles for next-generation batteries.

Lithium-metal battery innovation is vital as the world pivots to sustainable energy and transportation. The POSTECH-Chung-Ang research offers a blueprint for overcoming the primary impediments that have stalled lithium metal batteries’ commercial adoption: safety, longevity, and manufacturability. The implications extend beyond electric vehicles into grid storage, portable electronics, and advanced robotics applications where energy density and safety are pivotal concerns.

This research initiative was supported by the Ministry of Science and ICT of the Republic of Korea, reflecting a strategic investment in building domestic and global leadership in battery technology innovation. The outcomes reported in Advanced Materials on October 13, 2025, mark a milestone in the advancement of safe, high-capacity energy storage solutions that could redefine how we power mobility and technology in the coming decades.

Subject of Research: Lithium Metal Battery Engineering and Safety Enhancement

Article Title: Regulating Polymer Demixing Dynamics to Construct a Low-Tortuosity Host for Stable High-Energy-Density Lithium Metal Batteries

News Publication Date: 13-Oct-2025

Web References: 10.1002/adma.202510919

Image Credits: POSTECH

Keywords

Applied sciences and engineering; Electrochemical cells; Energy storage; Robotic power systems; Lithium ion batteries; Batteries; Electrochemistry; Solid electrolytes; Electrolytic conductivity; Nutrients; Electrolytes

In a groundbreaking paper recently published in the journal Electrochimica Acta, Drexel’s research team introduced a novel ultrasonic testing methodology that promises to revolutionize how manufacturers evaluate the integrity of batteries. This technique is designed to scrutinize the electrochemical and mechanical functions of batteries, effectively identifying any damage or flaws that may lead to overheating and the dreaded phenomenon known as "thermal runaway." This catastrophic event has been known to result in battery fires, explosions, and even widespread recalls of consumer electronics.

Dr. Wes Chang, a pivotal member of the research team and an assistant professor at Drexel University, emphasized the importance of this innovative approach. "Despite lithium-ion batteries having been in existence for nearly fifty years, our understanding of their internal structures remains limited. The techniques we have developed offer a high-resolution view into battery internals, making it possible to detect issues before they escalate into serious problems," he remarked. The adaptation of ultrasound technology, traditionally utilized in fields such as geophysics and biomedical sciences, offers a fresh perspective on battery diagnostics. Its introduction to the battery industry within the last decade is a game-changer that could have far-reaching implications on battery safety.

The team has crafted an accessible benchtop ultrasonic tool, aimed at empowering battery engineers with the capacity to conduct rapid assessments of battery integrity. This advancement seeks to bridge a gap in battery manufacturing, particularly amid a backdrop of increased demand for various electronic devices powered by lithium-ion cells. Reports indicate that the average individual uses three to four battery-operated devices daily, a trend that has doubled in the past five years. The rush to meet this soaring demand often compromises quality control, resulting in subpar battery production processes.

"While the majority of lithium-ion batteries on the market today are safe and efficient, the overwhelming production numbers raise the specter of defects slipping through the cracks. When thousands of cells are deployed in electric vehicles, even a minuscule manufacturing flaw can propagate and affect an extensive array of batteries," Dr. Chang cautioned. Current safety protocols, rooted in visual inspection and selective performance testing, prove insufficient in identifying potential hazards. Though some manufacturers employ X-ray imaging to scrutinize battery architecture, this method faces criticisms for being time-consuming and expensive.

Recognizing the urgent need for enhanced quality control, the Drexel team’s ultrasonic approach presents a swifter, cost-effective alternative. Their methodology harnesses acoustic imaging technology, employing ultrasound waves that traverse the various materials found inside a commercial pouch cell battery. This process analyzes how the sound waves behave within the structure, providing valuable insights into its chemical changes and mechanical performance without disrupting the cell’s functions.

By observing alterations in sound wave transmission, researchers can infer an array of structural features within the battery, thus pinpointing precise areas of stress, defects, or even gas accumulation—a critical indicator of battery health that could herald potential failure. The ultrasound technique’s sensitivity further extends its application beyond mere manufacturing defects; it proves invaluable during the materials discovery phase in research and development labs.

In collaboration with SES AI, a burgeoning lithium metal battery startup, Chang and his team realized the practical applications of this technology in real-time settings. By integrating this ultrasonic system within SES AI’s research facility, engineers benefit from immediate access to diagnostic data during the design and testing phases, fostering rapid iterations and improvements in battery designs.

In addition to reporting on the practical techniques for battery testing, Drexel’s team also developed open-source software to facilitate the use of their ultrasonic tool. This user-friendly interface streamlines data analysis, allowing researchers to focus on improving battery technology rather than grappling with complex instrumentation. "Our aim is to make ultrasonic testing a routine part of battery research and engineering," Chang added, reiterating the accessibility of this technology for a new generation of battery scientists intent on enhancing safety and performance.

Looking forward, the research group is committed to continually refining their techniques, aspiring to enhance the capability of ultrasound to produce detailed, three-dimensional scans of battery electrodes and cells. These advancements could offer an even clearer perspective on defects, allowing manufacturers to preemptively address critical issues and improve overall battery performance.

The significance of this research extends beyond academia and into practical applications that could reshape consumer electronics and electric vehicles. As the global market for battery-powered devices expands, the implications of increased battery safety and quality assurance have never been more pertinent. The Drexel University team’s pioneering efforts highlight the ongoing need for innovation in battery technology, aligning with broader trends toward cleaner energy and sustainable practices in transportation and beyond.

With their recent findings, the Drexel researchers are not just aiming to prevent battery fires but are also steering the conversation toward making lithium-ion batteries safer and more reliable for consumers everywhere. Their work marks a critical step in addressing the unique challenges posed by contemporary battery applications, underscoring the necessity of evolving quality assurance methods in line with automotive and technological advancements.

Ultimately, as industries increasingly pivot toward battery-driven solutions, the integration of advanced testing methods like ultrasound may well prove essential for ensuring the integrity and safety of the very devices that power our modern lives.

Subject of Research: Ultrasonic testing for battery safety and quality control
Article Title: Design of a low-cost ultrasonic testing instrument for battery metrology
News Publication Date: 1-Jun-2025
Web References: https://www.nytimes.com/2025/01/28/world/asia/busan-plane-fire-south-korea.html, https://www.inquirer.com/transportation/septa-bus-fire-preliminary-investigation-20250606.html?query=bus%20fire, https://www.sciencedirect.com/science/article/pii/S0013468625003755, https://www.theverge.com/2018/8/13/17675376/battery-safety-lithium-ion-solid-state-electrolyte-analysis, https://www.consumeraffairs.com/cell_phones/cell-phone-statistics.html, https://vimeo.com/1090093086, https://www.theverge.com/2016/9/2/12777320/samsung-galaxy-note-7-recall-battery-explosion, https://www.ses.ai/
References: N/A
Image Credits: N/A

Keywords