Tesla is reportedly planning to release four versions of its 4680 battery cells with dry-coated cathodes by 2026, each tailored for different vehicle models and purposes. The 4680 cylindrical cell, featuring dry-coated electrodes, was introduced at Tesla’s Battery Day event in 2020. While these cells are now being integrated into some Tesla vehicles in the United States, they currently utilize cathodes coated through the conventional wet process. For instance, the Cybertruck is expected to employ a hybrid version combining a dry-coated anode with a wet-coated cathode.
Earlier this year, reports indicated that Tesla aims to mass-produce 4680 cells with fully dry-coated electrodes before the end of 2024, with initial testing conducted in a prototype Cybertruck. According to a report by The Information, Tesla plans to develop four variants of the fully dry-coated 4680 cylindrical cells (46mm diameter, 80mm height). The planned variants, codenamed NC05, NC20, NC30, and NC50, are each designed for specific applications.
The NC05, described as the “workhorse,” is intended for use in the upcoming Robotaxi, set to be presented on October 10, the Cybertruck, and the Semi truck, indicating a focus on long-term durability. The NC20 is designed to offer higher energy capacity and will be used in another version of the Cybertruck, an electric SUV, and future Tesla models.
The top-tier versions, NC30 and NC50, will incorporate silicon components into the anode, enhancing battery performance over pure graphite anodes through a silicon-carbon mixture. The NC30 is slated for the Cybertruck and a sedan, while the NC50 is aimed at high-performance vehicles, such as a potential second-generation Tesla Roadster.
Traditionally, battery electrodes are produced using a wet coating process. This involves mixing active material powders with solvents and other chemicals to create a paste, which is then applied to a carrier film and dried in large, energy-intensive ovens. The dry-coating process eliminates the need for solvents and drying ovens, reducing energy consumption and production costs. It also allows for a smaller production footprint and reduces the size and expense of the required clean rooms.
Despite these advantages, the development of dry-coated electrodes has encountered challenges. As of mid-2024, it was reported that the performance and cost targets for the new cells had not yet been met. Tesla CEO Elon Musk reportedly urged the battery team to reduce costs by the year’s end and advance this critical innovation, likely referring to the dry-coated cathode technology.
Source: Teslarati
