Stresses resulting from electrode material chemomechanics are strongly coupled to solid electrolyte-electrode interface failures. Such failures are significant barriers to realization of practical Li-metal solid-state batteries (SSBs). We show the importance of cathode chemomechanics at commercially relevant low stack pressures (e.g., <1 MPa). Utilizing these learnings, we build long cycle-life SSBs with practical areal capacity (5 mAh/cm2) operating at less than 1 MPa stack pressure at room temperature.

Natrion is the manufacturer of Active Separator, a thin, flexible solid-state electrolyte separator for lithium secondary batteries. Natrion will present its latest validation of the performance and safety of semi-solid lithium-metal batteries pairing Active Separator with 5-20 micrometer-thick lithium-metal anodes. This will include cyclability of high-capacity pouch cells at ambient temperatures and pressures (zero clamping) demonstrating 1000+ Wh/L, 400+ Wh/kg energy densities, as well as independent abuse testing results.

A comprehensive understanding of the mechanisms that lead to cell failure in lithium-ion batteries is essential for the advancement of global battery sector. Robust detection methodologies are required to identify the onset of failure at early stages. In this study, we employ a combination of electrochemical analysis and advanced characterisation techniques to investigate the electrochemical phenomena occurring within cathodes and anodes. Utilising a three-electrode pouch cell configuration with lithium iron phosphate as the reference electrode, we assessed the electrochemical behaviour of both cathodes and anodes as cells approach unsafe conditions. For detailed characterisation, plasma focused ion beam (PFIB) scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (HAXPES and XPS) were conducted ex situ on cathode and anode materials. Additionally, operando nuclear magnetic resonance (NMR) spectroscopy was performed to elucidate failure mechanisms under extreme operational scenarios. The results establish a systematic methodology for identifying critical markers indicative of cell safety risks, offering potential for adaptation and implementation across a range of commercially relevant cell formats.

In parallel with cylindrical cells, prismatic cells are currently the format of choice for lithium-ion battery (LIB) electric vehicles (EVs). From a research and safety perspective, it is important to understand how the cell manufacturing impacts the operational behavior of these high-capacity cells. Here we present a safe methodology for the forensic analysis of commercial prismatic cells, not only in terms of evaluating cell component design and assembly, but also the electrode chemistry considerations. The aim of the study is to understand the physical aspects of manufactured cells including materials engineering considerations, such as a thorough study of the quality in the welding of the current collectors to the tabs. 3-electrode cells are manufactured from the commercial prismatic cells and their electrochemical performance is evaluated. Additionally, a novel Rayleigh-scattering-based distributed optical fibre sensor was used to deliver thermal images of the large prismatic cell. Using an optical fibre of 1 mm diameter wrapped around the cell, the optical sensor delivered over 400 unique measurement locations at 3 mm spatial resolution. During a 1.0 C charge, the optical-measured maximum temperature difference was 8.2 ◦C, while point-like thermocouples, located at the cell front surface and rear surface centre, only had a 0.8 ◦C maximum temperature difference. Finally, For the first time, a method was developed to instrument commercially available prismatic cells without releasing the internal pressure generated during formation. Our method demonstrates that internal pressure in commercial cells can be measured without compromising the cell’s electrical performance or incurring pressure loss.

Battery thermal propagation represents one of the most critical safety challenges in modern energy-storage systems, particularly as battery-pack energy densities continue to increase across automotive, stationary storage, and consumer applications. This presentation focuses on analysis and examines current solution trends; compares protection strategies at cell, module, and pack levels; and evaluates chemistry-specific approaches to mitigating thermal-runaway propagation.

Metallized polymer current collectors for the cathode have been demonstrated to consistently (27 of 27 trials) tolerate nail penetration (shallow or deep) in 21700 cell designs that achieve >250 Wh/kg when coupled with isotropic strength polymer separators and a thermally-stable ceramic coating on the anode active material. Only soft shorts develop and thermal runaway is obviated. High-speed radiography, cell OCV and temperature measurements, and post-test CT images of the nail holes reveal insights into the isolating mechanism. These innovative inert cell features can dramatically improve the safety of the vast majority of Li-ion cell chemistries.

Lithium-ion batteries used for portable applications are getting significantly large in terms of energy, and pose fire hazards of concern in the cargo compartments of aircraft. Studies have been carried out that include thermal runaway tests on these batteries ranging from a few tens of Wh to about 350 Wh. Suppressants that include Halon 1301, water, and water additives have been tested to characterize the efficacy of suppression.

Electric vehicle (EV) battery packs pose safety risks during saltwater submersion, as seen in recent hurricane-related incidents leading to thermal runaway. This study examines pack vulnerabilities through teardowns and full-scale immersion tests, identifying failure modes such as seal weaknesses, component degradation, and pathways to thermal runaway. Results show current immersion standards do not ensure safety under prolonged flooding. Early diagnostic signals were also identified, offering potential early warnings before failure. These findings support improved pack design, early-warning systems, updated standards, and emergency response strategies for saltwater-flooded EVs.

Battery packs in electric vehicles rely on sparse temperature sensing, often as little as one sensor for every ten cells, yet this limitation is rarely addressed in thermal runaway detection research. This talk evaluates how effective these low-cost temperature measurements are for early fault detection, using a combined modelling and experimental approach. It critically compares temperature-based diagnostics with alternative sensing methods, demonstrating that despite limitations, temperature sensing remains the most viable solution for scalable, cost-constrained battery management systems.

Early thermal-runaway detection in scaled electric-vehicle battery systems remains challenging due to sparse sensing and signal averaging across parallel-connected cells. This study experimentally evaluates advanced gas sensors and high-voltage electrochemical impedance spectroscopy in commercial Tesla modules housed in a pack-representative enclosure. Controlled single-cell overheating was used to assess diagnostic response at module scale, addressing the gap between cell-level validation and full-pack implementation.

This presentation discusses recent battery energy storage system codes and standards updates, and some corresponding safety approaches and best practices.

A summary of current and future EV and BESS requirements & regulations, comparing similarities and differences across both industries and why they exist.

This presentation will examine cycling-induced electrode deformation and the associated potential safety implications.

Electrolyte flammability is a critical safety and deployment barrier for next-generation batteries. This presentation introduces standardized flash point measurements applied to both aqueous-organic and gel-polymer electrolytes, providing quantitative insight into ignition risks across liquid and quasi-solid systems. By linking flammability to solvent composition, solvation structure, and polymer-solvent interactions through spectroscopic and data-driven analysis, we highlight key design rules to mitigate volatility and combustion risk. These results offer actionable guidance for industrial development of safer, high-performance electrolyte formulations.

This talk presents the charge-discharge cycling performance of laminated zinc rechargeable batteries using SoE (segmentation of electrolyte) technology for electric vehicles (EVs) and stationary energy-storage applications. This technology suppresses zinc dendrite formation during charging, enabling high durability with stable voltages and high voltage efficiency.

This talk uses multi-scale safety analysis methods to mechanistically assess the safety of commercial sodium-ion batteries for a comparison to state-of-the-art high-nickel lithium-ion. The same methods are then applied to prospective solid-state battery chemistries for predictive safety assessment.