Savings Calculator
This basic calculator is meant to provide a high-level overview of the impact AM Batteries’ dry electrode process can have on a battery manufacturing plant vs. the conventional slurry coating process.
Only seven inputs are required to demonstrate the impact dry has on operational and product costs.
Outputs
Cell Cost
($/kWh)
CO2 Impact
(kg CO2)
Op Costs
($/kWh)
Real Estate
(sq. ft)
How does AM Batteries
Differentiate from Other Dry Methods?
Dry electrode manufacturing can be broken into 2 primary categories, with multiple underlying subcategories and methods:
Powder to Electrode™
AM Batteries - Dry Deposition
Powder deposited onto foil → compressed
Extrusion
e.g., Maxwell/Tesla
Powder → free-standing film → foil compression
Both methods accomplish the goal of removing solvents from the electrode manufacturing process, but have differences in materials, mixing, deposition, footprint, and energy usage.
AM Batteries Powder to Electrode™
Dry Extrusion Coating
Slurry Coating + Drying
COATING PROCESS
Materials
Mixing
Coating
Edge
Formation
Compression
CELL
Electrolyte
Wetting
ECHEM
Performance
Requires PTFE
Tighter process control to activate binder without forming “goo”
Material calendared into a thick film then onto the current collector
• Thin coatings and layering difficult due to web tension and surface smoothness
• Tandem dual-sided
Edges / lanes film trims need to be remixed for recycling
Multiple rolls for densification and
compression to current collector
Slower to wet due lower surface energy of PTFE
PTFE degradation at anode potential
Flexible binder chemistry
Extremely fast; low capex; high mix filled volume
Material deposited directly onto current collector
• Supports thick, thin and layered coatings
• Side A → B
Excess powder directly recycled back into coater
Single step compression of powder into current collector
Faster to wet due to higher surface energy binder
Higher performance
• Flexible binder system
• Lower tortuosity