Many automakers spent the past few years racing to electrify their lineups, betting heavily that global demand for electric vehicles would surge. The industry poured billions into new EV battery plants across the world, particularly in North America.

Now, a new report suggests that much of that production capacity could end up sitting idle by the end of the decade.

Overcapacity Ahead

AlixPartners speculates that global production of EV batteries will be roughly three times greater than demand for EVs in 2030. By that time, EV battery production capacity in North America is expected to roughly quadruple.

According to Nikkei Asia, many manufacturers are already scaling back their ambitious battery production plans. Ford, one of the most aggressive investors in U.S. battery manufacturing, is a prime example. The company is building a $5.8 billion facility in Kentucky with its partner SK On, which is expected to employ about 5,500 people by 2030.

Read: Massive US Battery Plant Grinds To A Halt After Trump’s Tariffs

However, the Blue Oval already reduced its planned battery capacity by 35 percent. It also recently halted production of the F-150 Lightning indefinitely due to dwindling demand in North America.

General Motors has also been forced to make changes. It has been confirmed that 1,550 workers at the battery plants it operates alongside LG Energy Solution in Ohio and Tennessee will be sacked due to “slower near-term EV adoption and an evolving regulatory environment.”

Nikkei Asia also reports that Panasonic opened a new battery factory in Kansas in July, but has yet to say when it will reach full-scale production. Initially, it was expected to hit this mark by the end of the 2026 fiscal year. However, as a major supplier to Tesla, it has been affected by the fall in demand for EVs as well.

Slowing EV sales in the States have led to the cancellation of some endeavors entirely. T1 Energy was planning to build a battery plant in Georgia, but has since canned the project.

Changing Policy Winds

The Trump administration’s policies have further tilted the scales toward internal combustion vehicles. By removing the $7,500 federal EV tax credit and scrapping penalties for missing emissions targets, the government has made it easier for carmakers to ramp up traditional ICE production once again.

Source: Nikkei Asia

A new British company with bluechip supercar connections reckons it’s cracked one of the biggest bottlenecks in electric car tech: how to keep batteries cool enough to charge at full speed.

Hydrohertz, a UK startup led by an engineer whose resumé includes work for McLaren, Singer Design and Land Rover, has created hardware that could make long charging stops a thing of the past.

Smarter Thermal Control

It’s called the Dectravalve, and it’s a smart, compact control unit that precisely manages the temperature of each section of an EV battery, instead of treating the whole pack as one big lump. That means every cell stays at the same optimum temperature – no hot spots, no wasted cooling, and no thermal throttling.

Also: Chinese Brand Reveals Game-Changing 808-Mile Solid-State Battery

The result? A 10–80 percent charge, which typically takes around 30 minutes on a 400-volt EV even when hooked up to the fastest available DC charger, could drop to just 10 minutes.

That’s still a bit longer than it takes to fill up a petrol car, but it’s not far off. And faster fills aren’t the only promised benefit. Because the Dectravalve keeps the whole pack at its sweet spot all the time, and not just during charging, Hydrohertz says it can boost real-world range by up to 10 percent, which could be worth 30 or even 40 miles (48-64 km).

Other bonuses include extended battery life, a reduced risk of thermal runaway, and probably more consistent maximum-attack acceleration for performance EVs used in anger.

What The Data Shows

Hydrohertz tested its setup using a 100 kWh LFP battery, and the results are impressive. The hottest cell stayed under 44.5°C (112 F), with just a 2.6°C (37 F) variation across the entire pack. Most current systems see swings of 12°C (54 F) or more, forcing chargers to slow down once things heat up past 50°C (122 F).

Keep the temperature perfectly balanced, though, and the battery can safely accept maximum power right to the end.

A Shortcut To Better EVs

The system is also “chemistry agnostic,” meaning it’ll work with any current or future battery tech. That means it’s far cheaper than developing an all-new pack from scratch, which could make it a tempting upgrade for carmakers looking to squeeze more performance out of existing designs rather then spend big on solid-state packs.

“The automotive industry has been waiting for battery technology to catch up with consumer expectations, but progress has been slow and expensive,” says Hydrohertz CEO Paul Arkesden.

“A new chemistry can take a decade to develop and require billions in investment. What we’ve done is take a different approach. For OEMs, this means better, more useable EVs now, without waiting for the next generation of battery technology.”

Toyota has announced plans to invest an additional $10 billion in the United States over the next five years. The company didn’t say where the money is going or what it will fund, but it will bring their total U.S. investment to nearly $60 billion.

While the automaker was coy on specifics, the move comes amid tariffs and pressure from the Trump administration to build more vehicles in the United States.

Just last month, the White House said “Toyota plans to export its U.S.-made vehicles to Japan and open its distribution platform in Japan to U.S. automakers.”

The country also decided to allow sales of American-made vehicles and “U.S. safety-certified vehicles” without additional testing.

An American Battery Plant

Putting politics aside, Toyota Battery Manufacturing North Carolina has officially opened and begun production. Located in Liberty, the $13.9 billion plant is the company’s eleventh manufacturing facility in America and Toyota’s only battery plant outside of Japan.

It’s expected to generate up to 5,100 jobs and be capable of producing 30 GWh of battery capacity annually. While the opening comes shortly after the clean vehicle tax credit was eliminated, Toyota noted the plant has 14 battery production lines that support not only electric vehicles, but also hybrids and plug-in hybrids.

Speaking of which, batteries made at the plant will be used in the Camry Hybrid, Corolla Cross Hybrid, and RAV4 Hybrid. It will also make batteries for the company’s upcoming three-row EV.

While production is just getting started, Toyota plans to open additional assembly lines by 2030. The company also noted that once construction is complete, the facility won’t just be a workplace as it will also house a pharmacy, a medical clinic, a fitness center, and on-site childcare.

Toyota Motor North America CEO Tetsuo Ogawa remarked, “Today’s launch of Toyota’s first U.S. battery plant and additional U.S. investment up to $10 billion marks a pivotal moment in our company’s history. Toyota is a pioneer in electrified vehicles, and the company’s significant manufacturing investment in the U.S. and North Carolina further solidifies our commitment to team members, customers, dealers, communities, and suppliers.”

Owning a Ford F-150 Lightning means saying goodbye to gas stations forever. That’s the promise, at least, though it comes with the unspoken reality of long waits while electrons trickle into the battery. On the bright side, your truck can double as a backup power source for your home, and if Ford’s to be believed, even earn a few bucks while it sits in the driveway.

Read: F-150 Lightning Production Halted Indefinitely As Ford Bets On Gas Trucks Again

The company is eager to promote its usefulness, recently dedicating an entire piece describing how owners can turn their EV into a “side hustle”.

How Does It Work?

For some time, Ford’s Energy Rewards program has provided customers with bonuses for charging their F-150 Lightnings during off-peak times. It also has a system that allows the truck’s battery to serve as a backup generator during outages and blackouts.

In select US markets, owners can now charge their Lightning when electricity is cheaper (typically overnight during off-peak hours) and use the stored energy to power their home when grid prices are higher during peak times.

That’s not all. Customers can also return excess power from the F-150 back to the grid and get incentives from participating utility providers. According to Ford, customers can save up to $42 per month, or almost $500 per year, by using its new Home Power Management software.

The program has been launched in partnership with DTE Energy in Southeast Michigan. DTE will provide eligible owners the means to transfer power from the EV to their home.

Everything happens automatically, too, meaning the software optimizes the flow of energy to and from the battery pack while retaining battery health.

F-150 Lightning Production Paused Indefinitely

While the system is clever, it hasn’t done much to change the Lightning’s overall fortunes. Despite being the best-selling electric pickup in America this year, sales still trail Ford’s early projections. Earlier this month, production was officially paused with no restart date in sight.

With the federal EV tax credit gone and fuel economy penalties no longer enforced under the Trump-era rollback, Ford appears to be easing away from the Lightning experiment. The company now plans to build over 45,000 additional combustion-powered F-150s next year, signaling a quiet retreat to familiar ground

Around 80 percent of global energy production today comes from the combustion of fossil fuels. Combustion, or the process of converting stored chemical energy into thermal energy through burning, is vital for a variety of common activities including electricity generation, transportation, and domestic uses like heating and cooking — but it also yields a host of environmental consequences, contributing to air pollution and greenhouse gas emissions.

Sili Deng, the Doherty Chair in Ocean Utilization and associate professor of mechanical engineering at MIT, is leading research to drive the transition from the heavy dependence on fossil fuels to renewable energy with storage.

“I was first introduced to flame synthesis in my junior year in college,” Deng says. “I realized you can actually burn things to make things, [and] that was really fascinating.”

Deng says she ultimately picked combustion as a focus of her work because she likes the intellectual challenge the concept offers. “In combustion you have chemistry, and you have fluid mechanics. Each subject is very rich in science. This also has very strong engineering implications and applications.”

Deng’s research group targets three areas: building up fundamental knowledge on combustion processes and emissions; developing alternative fuels and metal combustion to replace fossil fuels; and synthesizing flame-based materials for catalysis and energy storage, which can bring down the cost of manufacturing battery materials.

One focus of the team has been on low-cost, low-emission manufacturing of cathode materials for lithium-ion batteries. Lithium-ion batteries play an increasingly critical role in transportation electrification (e.g., batteries for electric vehicles) and grid energy storage for electricity that is generated from renewable energy sources like wind and solar. Deng’s team has developed a technology they call flame-assisted spray pyrolysis, or FASP, which can help reduce the high manufacturing costs associated with cathode materials.

FASP is based on flame synthesis, a technology that dates back nearly 3,000 years. In ancient China, this was the primary way black ink materials were made. “[People burned] vegetables or woods, such that afterwards they can collect the solidified smoke,” Deng explains. “For our battery applications, we can try to fit in the same formula, but of course with new tweaks.”

The team is also interested in developing alternative fuels, including looking at the use of metals like aluminum to power rockets. “We’re interested in utilizing aluminum as a fuel for civil applications,” Deng says, because aluminum is abundant in the earth, cheap, and it’s available globally. “What we are trying to do is to understand [aluminum combustion] and be able to tailor its ignition and propagation properties.”

Among other accolades, Deng is a 2025 recipient of the Hiroshi Tsuji Early Career Researcher Award from the Combustion Institute, an award that recognizes excellence in fundamental or applied combustion science research.

© Photo: John Freidah/MIT MechE

It’s becoming increasingly clear that China has taken a commanding lead in the global race for electric vehicle and battery innovation. With the U.S. Department of Energy (DOE) pulling back on major Biden-era grants, that gap could widen even further

In early October alone, the DOE canceled more than $700 million in awards meant to boost domestic battery and manufacturing projects. The timing and scale of these cancellations have sparked frustration across the industry and in Washington alike.

Behind the scenes, reports suggest this may only be the beginning Recently, a list of projects reportedly being targeted by the DOE has been circulating among lobbyists, indicating that as much as $20 billion in awards could be scrapped.

Included in that list, and recently confirmed by the DOE, were $700 million in grants awarded under the previous administration for battery makers Ascend Elements, American Battery Technology Co, Anovion, and ICL Specialty Products. There was also a grant for glass manufacturer LuxWall.

What’s Behind The Cancellations?

In a statement, DOE spokesperson Ben Dietderich said the projects “had missed milestones, and it was determined they did not adequately advance the nation’s energy needs, were not economically viable, and would not provide a positive return on investment of taxpayer dollars.”

Read: Washington Could Break Biden’s $1.1 Billion EV Promise To GM And Stellantis

As noted by Politico’s E&E, the cancellation of these grants impacts plans to build large factories in states including Missouri and Kentucky.

Of the $700 million in grants, $316 million was awarded to Ascend Elements to support manufacturing components from recycled EV batteries at a $1 billion plant in Kentucky.

Additionally, $57.7 million was bound for American Battery Technology to support the construction of a Nevada plant producing lithium hydroxide for batteries. Elsewhere, $117 million was awarded to Anovion to support the production of synthetic graphite for lithium-ion battery anodes.

Energy Secretary Chris Wright is believed to be spearheading many of the cancellations, noting that “If they’re not in the interest of the taxpayers, if they’re not a good expenditure of the money, you always have the ability to cancel these projects.”

Democrats Hit Back

Unsurprisingly, Democrats quickly voiced their opposition. In a strongly worded letter to Wright, 37 Democratic and independent senators accused the DOE of overstepping its authority.

“The illegality of your cancellations is the only thing as indisputable as the harm your cancellations will wreak,” the letter stated. Lawmakers argued that the department “must expend these funds and faithfully execute the law, including many programs that have strict requirements for the timing of fund expenditure, purposes, and contractual expectations.”

Toyota has come under plenty of criticism in recent years for not making the shift to electric powertrains as quickly as some of its competitors. However, the world’s largest car manufacturer continues to invest heavily in EV technologies, doubling down on its commitment to launch new models with all-solid-state batteries in 2027-2028.

Since 2021, Toyota has been working with Japanese mining company Sumitomo Metal Mining on the cathode materials needed for solid-state batteries. These batteries, primarily composed of a cathode, anode, and solid electrolyte, have long been considered the holy grail of electric vehicles.

Smaller, Lighter, Faster

Beyond improving range, solid-state batteries are expected to be smaller, lighter, and charge faster than today’s lithium-ion packs. The technology is also said to deliver higher output and longer life.

Toyota recently signed a new agreement with Sumitomo Metal Mining to accelerate the mass production of these cathode materials, taking another step toward commercializing the technology.

Read: Toyota Partners With Japanese Petroleum Giant To Develop Solid-State Batteries For EVs

Toyota and Sumitomo say that through the use of powder synthesis technology, they have been able to develop a “highly durable cathode material” that can be mass-produced for these batteries. The collaboration builds on Sumitomo’s experience supplying cathode materials for existing EVs, now adapted to the stricter requirements of solid-state production.

It’s not just its work with Sumitomo that will allow Toyota to commercialize solid-state batteries. Since 2013, it has also been working alongside Japanese oil product Idemitsu Kosan on the new technology.

Idemitsu Kosan is developing lithium sulfide for use in batteries and plans to build a large plant capable of producing 1,000 metric tons of the material annually. Mass production is expected to start in 2027.

A previous roadmap published by Toyota indicated that its first generation of solid-state batteries launching in 2027-2028 will allow for 1,000 km (621 miles) worth of range, all while having the ability to charge from 10-80 percent in just 10 minutes.

The second generation is projected to exceed 1,200 kilometers (745 miles), signaling a substantial leap in energy density and efficiency.

In a statement, Toyota and Sumitomo said they are currently focusing on improving the “performance, quality, and safety of cathode materials for all-solid-state batteries, as well as reducing costs for mass production.” They aim to “achieve the world’s first practical use of all-solid state batteries in BEVs.”

Global Race For Solid-State Supremacy

While Toyota hopes to lead the transition, several global automakers are pursuing the same goal. BMW, Honda, Stellantis and Mercedes are investing heavily in solid-state technology, with some already testing prototype vehicles. Recently, MG launched the second-generation MG4 with semi-solid-state batteries that use around five percent liquid electrolyte.

Note: For anyone wondering, the opening image shows a pear-shaped lab flask containing a sample of solid-state battery material. Toyota included the photo in a release about its all-solid-state battery program.

Despite online jokes about the shape, it’s actually a standard scientific container used for drying and storing chemical samples during testing and production. The powder inside is cathode or electrolyte material destined for Toyota’s next-generation solid-state EV batteries.

In a market where federal tax credits are no longer cushioning electric car prices, the upcoming 2027 Chevrolet Bolt arrives as GM’s latest attempt to keep affordable EVs within reach. Shown off quietly to existing owners, the 2027 model rolls in at $29,990 including destination fees, offering a handful of upgrades over its predecessor rather than any sweeping reinvention.

Read: 2027 Chevy Bolt Just Showed Up Completely Undisguised At A Tesla Station

This represents a modest price increase over the 2023 model that was discontinued two years ago, and although it remains the most affordable EV from an American brand, the new Bolt still sits several thousand dollars above the entry-level 2026 Nissan Leaf, which is due to arrive next spring starting at $25,360.

Production and Core Specs

At a recent event, Chevrolet confirmed that production of the 2027 Bolt will begin early next year at its Kansas City facility. As revealed in recent images, the electric hatch will include a standard NACS charging port, aligning it with the new industry standard.

It has also been confirmed to come standard with a new 65 kWh lithium-ion phosphate battery pack that will provide it with 255 miles (410 km) of driving range, according to GM’s own estimates. That represents a modest improvement over the outgoing model’s 247-mile figure.

Photos Chevrolet

Beyond boasting a better range than the outgoing Bolt, the new one’s DC charging speeds are no longer capped at 50 kW. Instead, it can charge at up to 150 kW, meaning the battery can be topped up from 10-80 percent in 26 minutes. That’s a big improvement over the old model and matches the charging speeds of the new Leaf.

Chevy has also equipped the Bolt with a new motor, borrowing the unit found in the Equinox EV and producing 210 hp. Performance times have yet to be announced, not that Bolt owners are the kinds of buyers that’ll be participating in traffic light races.

Pricing and Trims

The 2027 Bolt will debut first as a Launch Edition, starting at $29,990 with destination and delivery included. A slightly more affordable LT trim will follow next year priced from $28,995.

From a visual standpoint, the alterations made to the Bolt are less significant than many had expected. Indeed, it mostly looks like a facelifted version of the outgoing model. Key changes made include the fitment of new headlights, different taillights, and a unique tailgate with a redesigned bumper.

The interior is also very similar. However, Chevy has added a larger digital instrument cluster and moved away from gear selector buttons on the transmission tunnel, instead opting for an electronic column shifter.

A particularly welcome addition is a set of large physical dials for temperature and fan speed, providing straightforward control without touchscreen fuss. Two new storage compartments now sit within the dashboard, directly in front of the passenger, adding extra practicality to the cabin.

Long charging times have long been considered one of the biggest disadvantages of electric vehicles, particularly when compared to how quickly you can refuel an ICE-powered car. However, Chinese automaker Zeekr has just unveiled an updated version of the 001 shooting brake, turning it into one that appears to be the fastest-charging EV on the planet.

Now, when we say the 001 charges as quickly as it takes to refuel a combustion-powered car, don’t rush to take a stopwatch to verify it, but it’s close enough to be quite impressive.

Lightning-Quick Refill

Thanks to the implementation of a new 900-volt electric architecture and Zeekr’s ‘Golden Brick’ battery, one version of the 001 can be charged from 10-80 percent in just 7 minutes.

Read: Zeekr 007 EV Can Get 80% Charge In Just Ten Minutes

That figure is particularly remarkable given that this model has a reasonably sizeable 95 kWh battery pack, rather than a small one that can charge quickly.

Zeekr claims the new and improved 001 supports charging speeds of up to 1,140 kW. In the US, only Tesla’s Megachargers, developed for the Semi, can deliver those kinds of speeds, but in China, Zeekr has already started rolling out 1,300 kW stations.

Power To Match The Speed

Zekr will sell the new 001 with the 95 kWh pack exclusively in all-wheel drive guise. This version features dual electric motors that combine to deliver 912 hp, allowing for a 0-62 mph (0-100 km/h) sprint in a dazzling 2.83 seconds.

The 95 kWh model has a claimed CLTC range of 441 miles (710 km), which is more than adequate even under China’s rather optimistic standards.

A version with a 103 kWh pack, using CATL’s Qilin battery tech, will also be available, boosting range to 437 miles (762 km), but not quite matching the charging speeds of the Golden Brick battery. That’s not to say models with the 103 kWh pack don’t charge quickly. In fact, they can go from 10-80 percent in just 10 minutes.

Plenty of other upgrades have been made to the Zeekr 001. For example, it comes with a panoramic glass roof embedded with individual LEDs that’s designed to mimic the Starlight headliner you’ll find in a Rolls-Royce.

The new model also includes a large infotainment display, a 39.3-inch head-up display, a 13-inch instrument cluster, and an 8-inch display at the rear.

Final pricing details have yet to be announced, but Zeekr has announced that customer deliveries will start in the coming days.

The Dacia Spring proved that EVs can be seriously affordable, so long as you can afford the time. The original versions were shockingly slow, but Dacia has replaced both the 46 and 65 models with two new versions that are on a different performance planet, and still shouldn’t cost the earth.

Until now, the Spring has come in a couple of trims and with two different motor options, the 45 and 65. Those numbers referred to the metric horsepower output, which equates to just 44 hp (33 kW) and 64 hp (48 kW).

Clearly, we’re not talking about Tesla-grade go here. The 65 took 13.7 seconds to reach 62 mph (100 km/h), and the 45 required 19.1 seconds, the kind of performance last seen on mainstream cars over 40 years ago.

Related: You Can Buy A New Dacia EV For Just $4,600 In Italy, But It’s Not For Everyone

Dacia hasn’t revealed a zero to 62 mph (100 km/h) time for the new 69 hp (70 PS / 52 kW) Spring 70, but it did provide some in-gear acceleration data to prove what a massive difference the extra muscle makes.

Where the 45 and 65 needed 26.2 and 14 seconds, respectively, to amble from 50-75 mph (80-120 kmh), the 70 can do the job in 10.3 seconds. And the 99 hp (100 PS / 74 kW) Spring 100 cuts it to just 6.9 seconds, while also getting to 62 mph in 9.6 seconds, which is hardly hot hatch performance, but it will certainly feel like one in this company.

Smarter Under The Skin

Helping keep that newfound punch in check is an anti-roll bar, which makes an appearance on the tech sheet for the first time, along with a new 24.3 kWh lithium-ion phosphate (LFP) battery. The electric driving range is unchanged at 140 miles (225 km), but the previously 30 kW on-board charger is upgraded to 40 kW.

That change looks laughable in the context of the latest 400 kW EVs, but the Spring’s battery is tiny, so a 20-80 percent fill takes a bearable 29 minutes when hooked up to a DC charger, and a 20-100 percent fill via a 7kW wallbox is done in 3h 20 minutes.

Price Still Matters

Dacia hasn’t revealed prices for the upgraded Springs, but hopefully, they won’t stray too far from where the outgoing cars were positioned. At just £14,995 ($20,200), the base 45 was one of the cheapest EVs available in the UK.

Dacia

Before batteries lose power, fail suddenly, or burst into flames, they tend to produce faint sounds over time that provide a signature of the degradation processes going on within their structure. But until now, nobody had figured out how to interpret exactly what those sounds meant, and how to distinguish between ordinary background noise and significant signs of possible trouble.

Now, a team of researchers at MIT’s Department of Chemical Engineering have done a detailed analysis of the sounds emanating from lithium ion batteries, and has been able to correlate particular sound patterns with specific degradation processes taking place inside the cells. The new findings could provide the basis for relatively simple, totally passive and nondestructive devices that could continuously monitor the health of battery systems, for example in electric vehicles or grid-scale storage facilities, to provide ways of predicting useful operating lifetimes and forecasting failures before they occur.

The findings were reported Sept. 5 in the journal Joule, in a paper by MIT graduate students Yash Samantaray and Alexander Cohen, former MIT research scientist Daniel Cogswell PhD ’10, and Chevron Professor of Chemical Engineering and professor of mathematics Martin Z. Bazant.

“In this study, through some careful scientific work, our team has managed to decode the acoustic emissions,” Bazant says. “We were able to classify them as coming from gas bubbles that are generated by side reactions, or by fractures from the expansion and contraction of the active material, and to find signatures of those signals even in noisy data.”

Samantaray explains that, “I think the core of this work is to look at a way to investigate internal battery mechanisms while they’re still charging and discharging, and to do this nondestructively.” He adds, “Out there in the world now, there are a few methods that exist, but most are very expensive and not really conducive to batteries in their normal format.”

To carry out their analysis, the team coupled electrochemical testing with recording of the acoustic emissions, under real-world charging and discharging conditions, using detailed signal processing to correlate the electrical and acoustic data. By doing so, he says, “we were able to come up with a very cost-effective and efficient method of actually understanding gas generation and fracture of materials.”

Gas generation and fracturing are two primary mechanisms of degradation and failure in batteries, so being able to detect and distinguish those processes, just by monitoring the sounds produced by the batteries, could be a significant tool for those managing battery systems.

Previous approaches have simply monitored the sounds and recorded times when the overall sound level exceeded some threshold. But in this work, by simultaneously monitoring the voltage and current as well as the sound characteristics, Bazant says, “We know that [sound] emissions happen at a certain potential [voltage], and that helps us identify what the process might be that is causing that emission.”

After these tests, they would then take the batteries apart and study them under an electron microscope to detect fracturing of the materials.

In addition, they took a wavelet transform — essentially, a way of encoding the frequency and duration of each signal that is captured, providing distinct signatures that can then be more easily extracted from background noise. “No one had done that before,” Bazant says, “so that was another breakthrough.”

Acoustic emissions are widely used in engineering, he points out, for example to monitor structures such as bridges for signs of incipient failure. “It’s a great way to monitor a system,” he says, “because those emissions are happening whether you’re listening to them or not,” so by listening, you can learn something about internal processes that would otherwise be invisible.

With batteries, he says, “we often have a hard time interpreting the voltage and current information as precisely as we’d like, to know what’s happening inside a cell. And so this offers another window into the cell’s state of health, including its remaining useful life, and safety, too.” In a related paper with Oak Ridge National Laboratory researchers, the team has shown that acoustic emissions can provide an early warning of thermal runaway, a situation that can lead to fires if not caught. The new study suggests that these sounds can be used to detect gas generation prior to combustion, “like seeing the first tiny bubbles in a pot of heated water, long before it boils,” says Bazant.

The next step will be to take this new knowledge of how certain sounds relate to specific conditions, and develop a practical, inexpensive monitoring system based on this understanding. “Now, we know what to look for, and how to correlate that with lifetime and health and safety,” Bazant says.

One possible application of this new understanding, Samantaray says, is “as a lab tool for groups that are trying to develop new materials or test new environments, so they can actually determine gas generation or active material fracturing without having to open up the battery.”

Bazant adds that the system could also be useful for quality control in battery manufacturing. “The most expensive and rate-limiting process in battery production is often the formation cycling,” he says. This is the process where batteries are cycled through charging and discharging to break them in, and part of that process involves chemical reactions that release some gas. The new system would allow detection of these gas formation signatures, he says, “and by sensing them, it may be easier to isolate well-formed cells from poorly formed cells very early, even before the useful life of the battery, when it’s being made,” he says.

The work was supported by the Toyota Research Institute, the Center for Battery Sustainability, the National Science Foundation, and the Department of Defense, and made use of the facilities of MIT.nano.

© Photo: Alexander Cohen

A German startup believes it has the recipe for electric vehicle battery cells that are cheaper, more energy dense, and less problematic for the environment than current lithium-ion cells. But commercialization seems a long way off. Theion announced Thursday in a press release that it is close to completing a 15 million euro (approximately $16.2...

Chinese researchers claim to have developed a process to recover nearly all of the lithium from used electric vehicle batteries for recycling. The Independent (via InsideEVs) reports on study results first published in the German academic journal Angewandte Chemie claiming recovery of 99.99% of lithium from a used battery, as well as 97% of nickel...

Deployment of 5-minute battery swaps could support hundreds of commercial EVs Ample says it's a straightforward retrofit, switching to its own battery packs Solution is less demanding on the grid than fast-charging stations California-based startup Ample is looking to deploy its battery-swapping tech with fleets of electric delivery trucks in...

Chinese battery firm CATL and automaker Nio are preparing to launch what the two companies claim will be the world's largest electric vehicle battery swapping network. CATL and Nio announced a technical partnership last year that included battery swapping, but on Tuesday they confirmed plans to start coordinating efforts as they build out battery...

SK On will supply batteries to Nissan for U.S.-made electric vehicles, the two companies announced Wednesday in a press release. Under the agreement, SK On will supply nearly 100 gigawatt-hours of batteries to Nissan from 2028 to 2033. They'll go into EVs produced at the automaker's Canton, Mississippi, assembly plant starting in 2028. Nissan...

Researchers in Norway are looking at ways to make electric vehicle battery cells more resilient. As part of an EU-funded project involving a series of battery suppliers and researchers, the Norwegian University of Science and Technology (NTNU) said in a recent press release (via Tech Xplore) that its researchers have been looking at different ways...

Honda is looking to source batteries from Toyota for U.S.-market hybrids amid continuing uncertainty over the Trump Administration's tariffs, Nikkei Asia reported Monday. Starting this fiscal year, Honda is planning to buy enough batteries for approximately 400,000 vehicles, according to the report. Honda sold 308,000 hybrids in the U.S. in 2024...

Once hyped as a potential cornerstone for an expanded European battery industry, Swedish battery maker Northvolt on Wednesday announced that it was filing for bankruptcy in its home country. "Like many companies in the battery sector, Northvolt has experienced a series of compounding challenges in recent months that eroded its financial position...