Why mass production is the final barrier for solid state batteries

Solid-state batteries hold significant promise for electric vehicles (EVs) by offering higher energy density, faster charging, and improved safety compared to traditional lithium-ion batteries. Lithium-ion technology, which currently powers most EVs and consumer electronics, is nearing its energy density limits—around 260 Wh/kg—necessitating heavier battery packs for longer ranges and requiring cooling systems to prevent thermal runaway. In contrast, solid-state batteries replace the liquid electrolyte with solid materials such as ceramics or polymers, enabling denser electrodes and potentially exceeding 400 Wh/kg energy density with lithium metal anodes. However, this architecture introduces challenges like high interfacial resistance, mechanical stress during cycling, and dendrite formation, which can cause short circuits. Unlike liquid electrolytes that self-heal electrode gaps, solid electrolytes require precise manufacturing techniques to maintain stable interfaces. The main barrier to widespread adoption of solid-state batteries is scaling up manufacturing to automotive levels. Researchers Mihri Ozkan and Cengiz Ozkan from the University of California