Metallic Fleece Enhances EV Battery Performance and Sustainability

German researchers at the Max Planck Institute have developed a groundbreaking battery material that improves performance and sustainability. Now brought to market by start-up Batene, this new metallic fleece replaces traditional flat metal foils in lithium-ion batteries. The innovation enhances energy storage, shortens charging time, and reduces resource use—key advantages for designers in the electric mobility and consumer electronics sectors.

A 3D structure for better conductivity

Most batteries today use thin copper or aluminium sheets to carry electrical charge. These sheets do not store energy themselves. Batene replaces them with a 3D metallic fleece that resembles a sponge or vascular network. This structure allows energy to move faster and more freely through the battery.

As a result, batteries made with this fleece can store up to 85% more energy and charge up to 56 times faster. These benefits are especially important for electric vehicles, where battery range and charging speed are major concerns.

Simpler production with fewer materials

Batene’s metallic fleece also changes how batteries are made. In standard cells, active materials must be layered carefully onto metal sheets. The new method allows powdered active materials to be added directly into the fleece. This process is easier and cheaper. It cuts production costs by around 30%.

The fleece also improves the battery’s lifespan. Its flexibility lets it absorb the expansion and contraction that happens during charging. This reduces wear and helps prevent early battery failure.

Improved safety and circular design

The metallic fleece improves safety by reducing internal resistance and preventing overheating. It also supports circular design goals. Because it uses fewer materials and lasts longer, the battery has a smaller environmental footprint.

For product and automotive designers focused on sustainable innovation, this material offers strong potential. It enables more powerful, efficient, and eco-friendly energy storage in electric vehicles, electronics, and tools.

Ready for next-generation battery chemistries

The batene fleece fits into existing production systems, making it easy to adopt. It also works with advanced battery types, including lithium-metal and solid-state designs. This means it can support future innovations in energy storage.

Founded in 2022, Batene is working with automotive partners to bring the material to market. The company has already received awards for its contribution to clean energy technologies.

Batene’s metallic fleece shows how material innovation can transform battery performance and sustainability. It’s a promising development for anyone designing electric vehicles, electronics, or other battery-powered products.

Source: Batene / Max Planck Society / Bright
Photo: Batene