Page 24 - PEN eBook October 2025

DESIGN
and mechanical characteristics tailored for different WHY Li-S BATTERIES?
applications. Li-S batteries have long been considered a promising
alternative to Li-ion batteries due to their high
This tunability is achieved through Lyten’s proprietary theoretical energy density and the abundance of sulfur.
manufacturing process, which allows precise control
over the material’s porosity, surface area, and Unlike traditional Li-ion batteries, which rely on
conductivity. The process begins with the extraction of expensive and often geopolitically sensitive metals
carbon from methane, a greenhouse gas. such as cobalt and nickel, Li-S batteries use sulfur as
the cathode material and lithium metal as the anode
Through a proprietary, patented reactor technology, material, achieving a theoretical energy density much
Lyten converts this carbon into a 3D supermaterial higher than that of conventional Li-ion batteries.
while simultaneously capturing hydrogen for reuse
as a clean fuel. This process also contributes to However, Li-S batteries have historically faced
carbon capture and the reduction of greenhouse gas significant challenges, including the polysulfide shuttle
emissions. effect, a phenomenon where sulfur compounds
dissolve into the electrolyte, causing rapid capacity
Lyten’s 55,000-square-foot fabrication facility in San degradation. Additionally, sulfur’s insulating nature
Jose is dedicated to the production of 3D Graphene and volume expansion during charge cycles further
and supports a range of product lines, including Li-S complicate the development of durable and efficient
batteries, lightweight composites, and advanced sensor Li-S batteries.
arrays.
Lyten’s tunable 3D Graphene addresses these
The company’s expansion strategy is further issues. Its mechanically flexible and electrically
evidenced by its acquisition of Europe’s largest conductive framework, combined with a hierarchical
battery energy storage system (BESS) facility in porous structure, allows it to act as a host for the
Gdansk, Poland (Figure 1), and plans to establish a sulfur cathode. This solution confines sulfur and
European headquarters in Luxembourg. its polysulfide intermediates within the cathode,
significantly mitigating the polysulfide shuttle effect by
preventing their dissolution and migration.
Furthermore, the inherent mechanical flexibility of
Lyten’s 3D Graphene enables it to accommodate the
significant volume changes of sulfur during cycling.
This structure maintains electrode integrity, prevents
pulverization, and ensures stable electrical pathways,
which are all essential for achieving a long cycle life.
Li-S ADVANTAGES AND LOCALIZED
SUPPLY CHAIN
Lyten’s approach to battery manufacturing offers
significant environmental and economic benefits. By
converting greenhouse gases into solid carbon for
3D Graphene production, the company’s process is
carbon-negative, contributing to global decarbonization
Figure 1: Northvolt’s former fabrication plant acquired by efforts.
Lyten (Source: Lyten Inc.)
The use of abundant and inexpensive sulfur, as
Lyten plans to promptly restart production in opposed to scarce and costly metals such as cobalt
Gdansk to resume sales of its BESS and is expanding and nickel, further reduces the environmental impact
its product lineup to feature the world’s first BESS and cost of battery production. This simplifies the
powered by Li-S batteries. supply chain and aligns with the growing demand for
sustainable and ethically sourced materials in the
Lyten intends to immediately restart production in energy storage industry.
Gdansk to resume sales of BESSes and is expanding its
product line to include the world’s first BESS powered Lyten has successfully demonstrated high-yield
by Li-S batteries. production of Li-S batteries on automated pilot lines,
24 OCTOBER 2025 | www.powerelectronicsnews.com
DESIGN
utilizing standard Li-ion manufacturing equipment.
This means existing gigafactories can be converted
for Li-S production with minimal capital expenditure
and time, accelerating the adoption curve.
Additionally, Lyten’s cathode manufacturing process
avoids the use of N-Methyl-2-pyrrolidone, a highly toxic
solvent commonly found in Li-ion battery production,
leading to a safer and more environmentally friendly
manufacturing footprint.
Figure 3: Lyten’s ultra-lightweight Li-S batteries powering
Lyten has also announced significant steps in UAVs (Source: Lyten Inc.)
achieving supply chain resilience. In April, the company
announced it had produced the United States’ first Lyten’s Li-S batteries can offer significant benefits
battery-grade lithium-metal foil (Figure 2) using lithium to the automotive industry. EVs equipped with these
alloys and lithium-metal sourced entirely from within batteries (Figure 4) could achieve longer ranges, faster
the U.S. charging, and reduced weight, addressing some of the
biggest consumer concerns about EV adoption. Major
automakers are already exploring partnerships with
Lyten to integrate this technology into future models.
Figure 4: Chrysler’s Halcyon Concept EV is planned to
incorporate Lyten’s 800-V Li-S batteries. (Source: Lyten Inc.)
In aerospace, where weight and energy density are
Figure 2: Lyten produces lithium metal alloy ingots as a critical, Lyten’s batteries could enable longer flight
key input for its U.S.-manufactured anodes used in Li-S times for electric aircraft and unmanned drones. The
batteries. (Source: Lyten Inc.) high specific energy of Li-S batteries makes them
particularly attractive for aviation applications, in which
Lyten has already established a fully localized supply every kilogram saved translates to improved efficiency
chain for its sulfur cathode and is now working and performance.
to do the same for its lithium-metal anode, laying
the groundwork for a resilient, tariff-free battery Lyten’s technological advancements have attracted
supply chain. Currently, much of the global battery the attention and investment of major industry
supply chain and the critical minerals it relies on are players. Strategic partnerships with companies such
dominated by China, presenting a significant strategic as Stellantis, FedEx, and Honeywell not only provide
vulnerability for the U.S. financial support but also facilitate the integration
of Lyten’s 3D Graphene and Li-S batteries into
APPLICATIONS AND automotive, logistics, and industrial applications.
STRATEGIC PARTNERSHIPS
Lyten’s Li-S batteries are already being deployed The company’s recent initiatives, including a $1 billion
in high-performance unmanned aerial vehicles gigafactory near Reno, Nevada, and a $650 million
(UAVs, Figure 3), are slated for demonstration on the letter of intent from the Export–Import Bank of the
International Space Station, and are being integrated United States, underscore its commitment to scaling
into advanced electric-vehicle concepts such as the production and meeting the surging demand for
Chrysler Halcyon. advanced batteries.
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