Sakuu demonstrates cycle life of dry-printed NCM electrodes

Sakuu reports new test data on lithium-ion electrodes manufactured dry on the Kavian platform. The focus is an NCM cell (NCM811 cathode, graphite anode) whose cathode was printed entirely using a dry process. According to the company, the validation cell retains 83 percent capacity after 4,000 full cycles. For comparison: for NCM cells in electric-vehicle applications, figures of over 2,000 cycles at around 80 percent remaining capacity are often considered a minimum target. Testing was performed on a 1-Ah format at 1C/1C.

Kavian manufacturing relies on additive, solvent-free electrode formation. This eliminates drying of conventional slurry coatings along with handling toxic solvents, reducing energy demand and process complexity.

“We’re so proud of the performance of Kavian-manufactured battery electrodes,” said Robert Bagheri, Sakuu founder, CEO, and executive chairman. “Our extensive testing confirms that Kavian’s dry manufacturing process can be reliably trusted to deliver a product that will meet or exceed the capabilities of current wet processes. This again dispels any doubts as to the suitability of using a dry process for printing lithium-ion (Li-ion) battery electrodes. This myth-busting achievement is a testament to our materials engineering expertise, as customers tell us other additive manufacturers experimenting with dry processes struggle to achieve satisfactory results across the entire printed electrode — particularly the cathode.”

Technically, the platform today supports cathodes and anodes in NCA, NCM, LFP, LTO, graphite, and silicon-graphite chemistries; according to Sakuu, the process control is also designed for alternative systems such as sodium- or aluminum-ion and solid-state approaches. In addition to batteries, supercapacitor electrodes can be produced on the same system, which is relevant for short-term power demands—such as in data centers. At the manufacturing level, Sakuu cites complete elimination of solvents and water, up to 60 percent reduction in required floor space, 30 percent lower utility operating costs, 55 percent less CO₂ emissions, and 20 percent lower capital expenditure.

Dry processes have long been considered a potential lever to reduce energy costs, facility footprint, and EHS requirements in electrode manufacturing. The decisive point is ensuring electrical conductivity, pore structure, and adhesion across the entire electrode thickness without a slurry. If the cycle-life and process data shown are confirmed in larger cell formats and under OEM-relevant load profiles, this will increase the pressure to incorporate dry coating in series production lines.