Page 25 - PEN eBook October 2025

DESIGN DESIGN

and mechanical characteristics tailored for different WHY Li-S BATTERIES? utilizing standard Li-ion manufacturing equipment.
applications. Li-S batteries have long been considered a promising This means existing gigafactories can be converted
alternative to Li-ion batteries due to their high for Li-S production with minimal capital expenditure
This tunability is achieved through Lyten’s proprietary theoretical energy density and the abundance of sulfur. and time, accelerating the adoption curve.
manufacturing process, which allows precise control
over the material’s porosity, surface area, and Unlike traditional Li-ion batteries, which rely on Additionally, Lyten’s cathode manufacturing process
conductivity. The process begins with the extraction of expensive and often geopolitically sensitive metals avoids the use of N-Methyl-2-pyrrolidone, a highly toxic
carbon from methane, a greenhouse gas. such as cobalt and nickel, Li-S batteries use sulfur as solvent commonly found in Li-ion battery production,
the cathode material and lithium metal as the anode leading to a safer and more environmentally friendly
Through a proprietary, patented reactor technology, material, achieving a theoretical energy density much manufacturing footprint.
Lyten converts this carbon into a 3D supermaterial higher than that of conventional Li-ion batteries. Figure 3: Lyten’s ultra-lightweight Li-S batteries powering
while simultaneously capturing hydrogen for reuse Lyten has also announced significant steps in UAVs (Source: Lyten Inc.)
as a clean fuel. This process also contributes to However, Li-S batteries have historically faced achieving supply chain resilience. In April, the company
carbon capture and the reduction of greenhouse gas significant challenges, including the polysulfide shuttle announced it had produced the United States’ first Lyten’s Li-S batteries can offer significant benefits
emissions. effect, a phenomenon where sulfur compounds battery-grade lithium-metal foil (Figure 2) using lithium to the automotive industry. EVs equipped with these
dissolve into the electrolyte, causing rapid capacity alloys and lithium-metal sourced entirely from within batteries (Figure 4) could achieve longer ranges, faster
Lyten’s 55,000-square-foot fabrication facility in San degradation. Additionally, sulfur’s insulating nature the U.S. charging, and reduced weight, addressing some of the
Jose is dedicated to the production of 3D Graphene and volume expansion during charge cycles further biggest consumer concerns about EV adoption. Major
and supports a range of product lines, including Li-S complicate the development of durable and efficient automakers are already exploring partnerships with
batteries, lightweight composites, and advanced sensor Li-S batteries. Lyten to integrate this technology into future models.
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 Figure 4: Chrysler’s Halcyon Concept EV is planned to
incorporate Lyten’s 800-V Li-S batteries. (Source: Lyten Inc.)
significant volume changes of sulfur during cycling.
This structure maintains electrode integrity, prevents
pulverization, and ensures stable electrical pathways, In aerospace, where weight and energy density are
which are all essential for achieving a long cycle life. 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
Li-S ADVANTAGES AND LOCALIZED batteries. (Source: Lyten Inc.) high specific energy of Li-S batteries makes them
SUPPLY CHAIN particularly attractive for aviation applications, in which

Lyten’s approach to battery manufacturing offers Lyten has already established a fully localized supply every kilogram saved translates to improved efficiency
significant environmental and economic benefits. By chain for its sulfur cathode and is now working and performance.
converting greenhouse gases into solid carbon for to do the same for its lithium-metal anode, laying
3D Graphene production, the company’s process is the groundwork for a resilient, tariff-free battery Lyten’s technological advancements have attracted
carbon-negative, contributing to global decarbonization supply chain. Currently, much of the global battery the attention and investment of major industry
Figure 1: Northvolt’s former fabrication plant acquired by efforts. supply chain and the critical minerals it relies on are players. Strategic partnerships with companies such
Lyten (Source: Lyten Inc.) dominated by China, presenting a significant strategic as Stellantis, FedEx, and Honeywell not only provide
The use of abundant and inexpensive sulfur, as vulnerability for the U.S. financial support but also facilitate the integration
Lyten plans to promptly restart production in opposed to scarce and costly metals such as cobalt of Lyten’s 3D Graphene and Li-S batteries into
Gdansk to resume sales of its BESS and is expanding and nickel, further reduces the environmental impact APPLICATIONS AND automotive, logistics, and industrial applications.
its product lineup to feature the world’s first BESS and cost of battery production. This simplifies the STRATEGIC PARTNERSHIPS
powered by Li-S batteries. supply chain and aligns with the growing demand for Lyten’s Li-S batteries are already being deployed The company’s recent initiatives, including a $1 billion
sustainable and ethically sourced materials in the in high-performance unmanned aerial vehicles gigafactory near Reno, Nevada, and a $650 million
Lyten intends to immediately restart production in energy storage industry. (UAVs, Figure 3), are slated for demonstration on the letter of intent from the Export–Import Bank of the
Gdansk to resume sales of BESSes and is expanding its International Space Station, and are being integrated United States, underscore its commitment to scaling
product line to include the world’s first BESS powered Lyten has successfully demonstrated high-yield into advanced electric-vehicle concepts such as the production and meeting the surging demand for
by Li-S batteries. production of Li-S batteries on automated pilot lines, Chrysler Halcyon. advanced batteries.

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