Electrodes

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Steps
Eliminated

10+

Density Improvement

Up to 100%

Emission
Savings

40%

Our Morhology

A True Solid-State Electrode

Our breakthrough DirectPlate™ production process enables a novel electrode architecture that is a revolutionary advancement in battery technology. We have devoted more than a decade of intensive research into developing lower cost, higher performance electrodes.

What makes our morphology different?

100% Active Material
Our single-step plating eliminates the need for binders and conductive additives, replacing today’s inefficient powder-based methods. By maximizing active material content, our process increases energy density by creating the only true solid-state cathode while reducing complexity in battery manufacturing.
Endless Applications
Our versatile process works across a wide range of substrates, not limited only to traditional foils, enabling design freedom in battery architecture. This flexibility supports advanced applications such as thin-film and micro-batteries, structural energy storage, and 3D-printed electrodes for next-generation devices.
Orientation Control
DirectPlate™ enables precise control over crystal orientation in LCO material, creating uniform structures that improve conductivity and stability. This structural alignment enhances battery performance, extending cycle life and enabling higher power delivery while meeting the unique needs of varied customer use cases.
True Innovation

Refusing to accept tradeoffs.

Process Change

Our breakthrough DirectPlate™ technology compresses the entire electrode production supply chain into a single-step, streamlined process — cutting time, capital, and footprint while enabling deep technical advantages.

Dual Advantage

Traditionally, innovation in battery technology focuses on improving either battery metrics or costs. With DirectPlateTM, Xerion will dramatically improve both resulting battery metrics and manufacturing costs.

Sustainable Power

Conventional battery material production requires heating battery materials to over 800˚C. In contrast, DirectPlate™ operates at much lower temperatures and eliminates the need for binders, solvents, and additives — reducing carbon emissions by 40% compared to legacy technologies.

Production Optimization

DirectPlate™ consolidates the full battery supply chain, including material refinement, CAM production, powder mixing, and electrode production, into one continuous process contained in a single device. This streamlined approach reduces labor, space, and cost while enabling flexibility across battery sizes and form factors.

Technical Advantages

Superior Electrodes

Significant Cost Improvement

DirectPlate™ refines, synthesizes, and deposits active battery materials in a single step, eliminating costly refining and transport in conventional slurry-cast manufacturing. By starting with lower-purity precursors, Xerion cuts electrode material costs compared to expensive battery-grade powders.

Greater Energy Density

Our novel battery technology architecture and manufacturing with DirectPlate™ removes the need for carbon additives and polymer binders found in legacy electrode manufacturing, allowing for electrodes to contain up to 100% active material with significantly higher energy density.

Higher Power and Faster Charging

Xerion's novel electrode nanostructure dramatically enhances performance by enabling ions to move through the battery significantly faster, reducing resistance and improving charge and discharge rates.

Increased Flexibility & Durability

DirectPlate™ forms robust electrochemical bonds with the aluminum foil current collector, creating stronger interfacial adhesion that significantly reduces the risk of delamination and mechanical failure during cycling.

Dramatically Safer

Our  architecture minimizes the potential for thermal runaway by lowering internal resistance and reducing localized heat generation during failure events, thereby enhancing thermal stability and overall battery safety under abusive operating conditions.

Improved Cycle Life

Our electrodes feature an enhanced architecture that accommodates the natural swelling of high-energy materials, alleviating the mechanical stress and particle fracture that typically cause electrode fatigue. This improved structural resilience reduces failure events and extends cycle life, even under demanding operating conditions.

Dramatic Footprint Reduction

Our manufacturing process eliminates a number of energy-intensive steps, which mitigate carbon emissions up to 40%. Our manufacturing process eliminates the use of toxic volatile organic compound solvents.

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Electrode Pilot Plant

Fully Operational for LCO Electrodes

Drastic step reduction

Using significantly less energy, time, and capital with lower purity precursors

Flexibility

No additional equipment required to change morphology being plated

Cost Advantage

Dramatic equipment footprint and cost savings compared to legacy production

where we can help

Market Applications

Aerospace & Defense
Consumer Electronics
Drones
Micro-Batteries

Aerospace & Defense

Defense platforms rely on advanced energy systems that provide high energy density, high power delivery, and resilience in extreme conditions. Xerion's electrodes can power:

Avionics and flight control systems
Unmanned ground vehicles
Emergency backup power
Wearable power packs

Consumer Electronics

Batteries power our everyday lives and require portability with high energy density, power, and flexibility. Xerion's electrodes can power:

Smartphones
Laptops
Wearables
Power tools

Drones

Lightweight, high-density energy systems will enable extended flight times, faster recharge cycles, and reliable performance for a variety of drones. Xerion's electrodes can power:

Consumer drones
eVTOLs
UAVs
Air taxis

Micro-Batteries

Packing 100% active material at a micro scale, enabling power storage in devices where size and precision are critical. Xerion's electrodes can power:

Medical devices
IoT sensors
Wireless communication
Environmental sensors