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Automotive Industry

New Assembly Line to Make Lithium-Metal Batteries for EVs

The state-of-the-art production line will assemble large-format battery cells exceeding 50 amp-hours.

Sion lithium-metal battery

Sion’s Licerion lithium-metal anode technology addresses the most significant barriers to mass EV adoption: range, cost and charge time. Photo courtesy Sion Power

May 7, 2025

TUCSON, AZ—Sion Power, a manufacturer of lithium-metal batteries for electric vehicles and energy storage, has installed a new large-format battery cell production line at its assembly plant here. 

Sion’s Licerion lithium-metal anode technology addresses the most significant barriers to mass EV adoption: range, cost and charge time. Licerion doubles the energy density of other battery technologies, surpassing graphite and silicon anode technologies. It is expected to reduce the cost of a 200 kilowatt-hour battery pack by 35 percent through a 15 percent cut in material costs and a 20 percent reduction in cell count. It also enables charge times comparable to a gas station’s 8-minute average refuel time.

Compared to traditional lithium-ion batteries, Licerion batteries offer twice the energy in the same size and weight. 

The state-of-the-art production line will assemble large-format battery cells exceeding 50 amp-hours. 

“The ability to scale performance from small prototype cells to large-format cells is often where battery technologies face the greatest challenge,” said Tracy Kelly, Sion Power president. “Our new manufacturing line bridges that gap, demonstrating the capability of our lithium-metal battery technology in formats applicable to real-world applications.”

Until now, Sion Power used an automated assembly line to produce a variety of cell formats, including lab-scale and 6 amp-hour cells, while using a semiautomatic line for larger-format cells. Adding the new line significantly enhances production efficiency and quality control for larger-format cells, which are essential for validating performance, cycle life and manufacturability at scale.

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KEYWORDS: battery manufacturing electric vehicles

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