Battery-makers are eagerly researching ways to incorporate silicon, which can potentially store 10 times as much energy as graphite, into anodes. Now silicon anode specialist GDI says it has developed a 100% silicon roll-to-roll processed anode for next-generation batteries, potentially enabling graphite-free battery cells that deliver far higher energy density, faster charging and greater safety than current cells.

GDI’s anodes have demonstrated specific capacity of over 3,200 mAh/g in third-party testing.

The new anode uses a 100% silicon architecture, bonded directly to copper alloy foil from Carl Schlenk, a provider of high-performance metal foils.

In partnership with plasma equipment and glass production specialist AGC, GDI has demonstrated MWh-scale roll-to-roll production on industrial equipment. The company calls this a proof of concept to show that its silicon anodes can be produced at GWh scale, delivered directly to cell makers and integrated directly into existing cell production lines.

Navitas nail penetration testing demonstrated impressive resistance to thermal runaway. After leaving a nail pierced through a 3.5 Ah cell with a GDI anode for 10 hours, there was no fire, no smoke, and temperatures only increased by 10° C.

GDI says it is already executing initial product development partnerships in medical and defense markets, and is simultaneously carrying out initial testing for the premium EV segment.

“Our mission at GDI is to deliver a 100% silicon anode that can be integrated into existing battery production, greatly reduces GHG emissions from the anode production, and scales rapidly on cutting-edge industrial equipment,” said GDI founder and CEO Rob Anstey. “In partnership with AGC and Navitas we have done all three. The next step is to show our anode can enable EV batteries that power vehicles with >500 miles of range, allows them to charge 250 miles in 15 minutes, hundreds of times, and improves safety. GDI and AGC have developed a clear roadmap to gigawatt-scale production by 2028, so that this technology can be used in tens of thousands of high-performance vehicles by 2030.”

Source: GDI