Sion Power has introduced a proprietary vacuum deposition process for manufacturing lithium-metal anodes, overcoming key limitations of traditional mechanical rolling. The new roll-to-roll thermal evaporation technique deposits lithium directly onto copper foil at precisely controlled speeds, enabling ultra-thin, uniform films as thin as 2–3 microns. This represents a significant reduction from the 30–50 micron thickness typical of mechanically rolled anodes and eliminates the need for lubricants and additives.
By tailoring film thickness between 2 and 50 microns, the process optimizes material usage and cost efficiency for different battery applications. It also supports engineered surface coatings that further improve lithium stability and electrochemical performance. In comparative customer testing, Sion Power’s 5-micron films delivered double the cycle life of equivalent competitor materials, demonstrating a clear performance advantage for next-generation batteries.
“Our ability to deposit lithium in films from 2 to 50 microns with custom surface treatments positions us as the leader in lithium-metal anode technology,” said Tracy Kelley, president and chief science officer of Sion Power. “This innovation provides a true scalable path to high-performance batteries.”
Unlike other approaches that adapt multi-industry tools, Sion Power’s methodology has been refined over decades specifically for battery anodes. The company has validated the process’s scalability through customer engagements that included detailed throughput and cost analyses. The vacuum deposition method is already in use for producing anodes in Sion Power’s Licerion large-format battery cells at its Tucson, Arizona, facility.
“With decades of expertise in lithium-metal, we believe our vacuum deposition method is the gold standard for thin lithium films,” said Kelley. “It is a U.S.-based solution ready to support commercial demand at gigawatt scale.”
Source: PR Newswire
