U.S.-based battery technology company Natrion has opened pre-orders for its first-generation Gen-1 Active Separator, the only lithium solid ionic composite (LISIC) separator of its kind made domestically. Manufactured in Upstate New York, the Gen-1 Active Separator is designed as a drop-in component for current gigafactory cell lines, offering an immediate upgrade path without production line modifications.
Internal testing of the 280 mm-wide separator roll in Li-ion pouch cells demonstrated a 10–15% increase in accessible capacity compared to cells using conventional inactive separators under identical charge–discharge conditions. In NMC811/Li-metal pouch cells, the active separator effectively blocks dendrite propagation, a common failure mode in legacy separators, and delivers 450 Wh/kg energy density performance—roughly a 50% improvement over standard Li-ion cells—while enabling 15-minute charge times.
Beyond performance gains, Natrion reports that the new separator widens operating temperature ranges and promotes benign failure modes, reducing fire risks. The material’s intrinsic ion-transport properties replace or augment liquid electrolytes, lowering the volume of liquid required and driving down cell bill-of-materials costs on a $/kWh basis. Mechanically, the Gen-1 material matches or outperforms legacy separators in thinness, flexibility, and tensile strength, making it compatible with jelly-roll, Z-fold, and other assembly processes.
Production capabilities, announced in fall 2024, have already been scaled to gigascale output to address a projected shortage of more than 5 billion square meters per year of onshore separator supply by 2030. Using only domestic raw materials and a tariff-insulated supply chain, Natrion positions the Gen-1 product as an IRA-compliant solution for manufacturers seeking fully U.S.-sourced battery components.
Conditional pre-orders are now being accepted, subject to availability, with full material specifications available on Natrion’s website. Founded in 2018, Natrion has received multiple Department of Defense contracts and collaborates with leading industry and academic partners, including LG Energy Solution.
Source: Natrion
