Advanced material specialist 6K’s division 6K Energy has been awarded $1.9 million under Battery Network (BATTNET) Program III from the U.S. Defense Logistics Agency (DLA).
Funding supports a 12 month research and development effort focused on lithium-ion battery materials for defense use. Work under the award centers on single crystal NMC721 cathode material. Activities include scaled synthesis using UniMelt microwave plasma processing, optimization of post processing steps, and electrochemical performance validation.
“We are excited about this program on many fronts,” says Dr. Saurabh Ullal, CEO of 6K Inc. and President of 6K Energy. “This award recognizes the capabilities of our UniMelt platform and validates our ability to produce NMC721 domestically and sustainably. We appreciate the confidence that the DLA and the BATTNET program have placed in 6K Energy, and we believe this effort will accelerate the delivery of high-performance NMC721 materials critical to our nation’s defense and energy security.”
Advancing NMC721 cathode manufacturing
Under this program, validation will be carried out through coin cell and full cell testing conducted with an undisclosed US-based lithium-ion cell manufacturer. Material is designed to operate within a 2.5 to 4.35 volt cell voltage range, consistent with requirements for battery cells manufactured entirely in the US for defense applications.
According to the company, single crystal NMC811 and other high nickel NMC materials have previously been supplied to original equipment manufacturers and lithium-ion cell producers for evaluation. The current development extends that activity by shifting focus to NMC721.
Single crystal NMC721 differs from polycrystalline cathode materials because it lacks grain boundaries. This structure can reduce intergranular cracking and lower electrolyte reactivity due to reduced surface area.
Conventional co-precipitation methods used to produce single crystal NMC721 typically require extended calcination times, use of flux additives, aggressive post processing, and generate waste. UniMelt processing is being evaluated under the program as an alternative manufacturing approach to address those constraints.
As Dr. Richard Holman, CTO of 6K Energy puts it, “This BATTNET award gives us the opportunity to push the boundaries for NMC721 and again demonstrate that our UniMelt technology can deliver highly sought-after, high-quality battery materials at scale right here in the United States.”
The BATTNET Program operates under Defense Operational Energy and is managed through Defense Manufacturing Technology. Program objectives focus on strengthening domestic battery supply chains, improving safety and shelf life, reducing premature disposal, and increasing battery availability for defense use.
New manufacturing paths for lithium-ion batteries
6K Energy’s award comes as multiple research groups and manufacturers explore alternative manufacturing approaches for lithium-ion battery components,
Recently, it was announced that Titomic and Rensselaer Polytechnic Institute (RPI) are evaluating CSAM as an alternative method for lithium-ion battery electrode production. Backed by the NSF Energy Storage Engine program, the project examines direct deposition of anode and cathode powders onto aluminum or copper foils, eliminating solvents, binders, and drying steps used in slurry based processes.
Technical work spans four phases, including material feasibility studies, micro and macro characterization, electrode demonstrator development with electrochemical testing, and pilot scale integration into roll to roll manufacturing, followed by scalability and cost analysis.
In September, Tel Aviv University and Rafael Advanced Defence Systems researchers demonstrated a fully functional lithium-ion battery fabricated entirely using inkjet drop on demand 3D printing. The method enabled sequential printing of cathode, separator, and anode layers using tailored inks, including an LFP cathode, a PVdF alumina composite separator, and a graphite anode.
Ultra thin layers were deposited with controlled droplet delivery, avoiding doctor blade processing and viscosity constraints. Electrochemical testing showed separator performance comparable to commercial membranes and stable full cell operation across C rates from C/20 to C/2.
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Featured image shows 6K UniMelt microwave plasma platform driving next-generation single-crystal NMC721 development. Photo via 6K Energy.
