#United States #Tucson #Sion Power #Licerion #lithium-metal

Sion Power Sets New Standards in Lithium-Metal Anodes

Sion Power, based in Tucson, Arizona, is paving the way for significant advancements in the realm of lithium-metal battery technology. On September 16, 2025, the company announced a groundbreaking vacuum deposition process designed to transform the manufacturing of lithium-metal anodes. This innovative method addresses some of the core limitations found in traditional anode production methods, thereby enhancing the overall performance and scalability of lithium-metal batteries.

Breaking Down Conventional Manufacturing Challenges

Historically, the production of lithium-metal anodes has relied heavily on mechanical rolling techniques. These methodologies restrict the thickness of lithium layers to approximately 30 to 50 microns and necessitate the use of lubricants and various additives during the production process. This reliance not only complicates manufacturing but also introduces inefficiencies and impacts the cost-performance ratio essential for competitive battery development.

Sion Power's new vacuum deposition process marks a pivotal shift from these traditional methods. By employing a roll-to-roll thermal evaporation approach, lithium can be expertly deposited directly onto copper foil at controlled speeds. This enables the creation of ultra-thin and uniform films, with thicknesses as low as 2 to 3 microns. The flexibility this method offers allows manufacturers to tailor lithium thickness specifically for different applications, reducing material waste and enhancing cost-effectiveness.

Enhancing Performance and Durability

Beyond merely improving the thickness control during the anode manufacturing process, Sion Power's vacuum deposition method facilitates the introduction of engineered surface coatings. These improvements significantly contribute to enhancing the stability and overall performance of the lithium-metal anodes. Recent customer evaluations have indicated that Sion Power's anodes, featuring 5-micron films, deliver cycle lives that are twice as long compared to competing materials, showcasing a distinct performance advantage.

Tracy Kelley, Sion Power's President and Chief Science Officer, stated, "Our ability to deposit lithium in films ranging from 2 to 50 microns with custom surface treatments positions us as the leader in lithium-metal anode technology. This innovation clears the way for a scalable path to high-performance batteries."

A Scalable and Focused Solution

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Unlike numerous companies that are exploring lithium-metal deposition techniques, Sion Power brings a unique and mature approach to the table. Rather than using equipment developed for other sectors, Sion Power has dedicated decades of research and development to refine a process that is specifically optimized for battery anode applications. This focus has resulted in a product that not only meets but exceeds industry expectations for scalability and performance.

Sion Power has further validated the effectiveness of its vacuum deposition process by collaborating closely with customers, engaging in extensive throughput and cost analysis. The process is currently operational for use in the production of anodes for the company’s Licerion® large-format battery cells, which are being manufactured at their Tucson facility.

Commitment to U.S.-Based Solutions

Tracy Kelley also emphasized the critical role Sion Power plays in the U.S. energy storage landscape. "With our longstanding expertise in lithium-metal technology, we believe our vacuum deposition method is the gold standard for thin lithium films. It is a U.S.-based solution ready to support commercial demand at gigawatt scales."

For those interested in learning more about Sion Power and its innovative solutions in battery technology, additional information can be found by visiting their official website at www.sionpower.com.

Conclusion

Sion Power’s advances in lithium-metal anode manufacturing through its proprietary vacuum deposition process not only set a new industry standard but also promise transformative impacts on the performance and scalability of lithium-metal batteries. With these innovations, Sion Power is well-positioned to lead the charge into a future dominated by enhanced battery technologies, ushering in an era of high-performance energy solutions.