OAK RIDGE NATIONAL LABORATORY

“Deployment is a key consideration for energy storage. ORNL is focused 

on the spectrum of battery development from basic science to benchtop 

prototypes to working with industry to develop manufacturing capability 

for the next generation of energy storage.”

—Electrification and Energy Infrastructure Section Head Ilias Belharouak

Battery Manufacturing

DEVELOPING

chemistries and 

materials

DESIGNING

cell architecture

DEMONSTRATING

prototype cells

ACCELERATING

energy-dense 

systems 

ACHIEVING

decarbonized 

energy

Batteries that can store more electricity in less space, charge very quickly, provide long-duration storage, and have a lengthy, safe operational 

life can accelerate the transition to a fully electrified transportation sector while supporting a modern, reliable, and clean power grid. Oak 

Ridge National Laboratory (ORNL) translates discoveries in materials and chemistries into battery prototype systems using solid electrolytes 

that result in lighter, faster-charging, compact, and more stable energy storage. The goal is a practical solid-state battery that can be easily 

scaled and built, speeding breakthroughs to the marketplace for a robust domestic battery manufacturing sector. 

Energy Storage Solutions

Nondestructive material layers 

joining—Developed a scalable low-cost 

electrochemical pulse method to join 

material layers in solid-state batteries, 

increasing contact between materials 

while preventing detrimental effects. The 

nondestructive method is easily scaled for 

solid-state battery manufacturing and can 

be used during routine maintenance to 

extend the battery’s life. 

Cobalt-free cathode technology—Created a suite of breakthroughs to support a cobalt-free 

cathode battery that has higher energy density without using costly overseas materials. Further 

developed and scaled the technology, including rapid manufacturing processes.

Strong, solid composite electrolyte—Fabricated a solid composite electrolyte film 

that is thin, mechanically strong, very conductive, and easily scaled for manufacturing. 

Scientists created a 3D interconnected structure to make a robust electrolyte with the 

potential for high energy density. 

Dendrite healing—Demonstrated a technique using an electrochemical pulse to eliminate 

metallic microstructures called dendrites that can appear in solid electrolytes during charging. 

Resolving dendrites can improve battery performance and prevent short circuits. 

Understanding heat transport—Proved that the heat transport ability of lithium-ion battery 

cathodes is much lower than previously thought. This knowledge can guide research on the 

development of high-density battery design. Researchers used quantum calculations to accurately 

predict heat transport.
Oak Ridge National Laboratory is managed by UT-Battelle LLC for the US Department of Energy January 2023

CONTACT:

Ilias Belharouak

Electrification Section Head

belharouaki@ornl.gov

865-576-7342

One Bethel Valley Road, 

Oak Ridge, TN 37831

Raw materials discovery and evaluation—Exploring advanced, high energy density cathodes and 

high-capacity anodes that do not rely on critical materials using limited availability

Characterization and testing—Enabling in-depth materials investigation with neutron science, 

high-performance computing, high-resolution microscopy, microstructural and magnetic 

characterization, high-resolution chemical mapping, 3D surface profiling, and mechanical pinch testing 

Advanced simulation and modeling—Speeding cell design prototyping by using advanced 

computational modeling and simulation to screen new battery materials, determine the effects of 

electrode-coating defects on cell performance, and develop accurate lifetime predictions

Complete battery manufacturing and evaluation—Integrating any component into a 

complete battery and analyzing how well it works and can be improved

Scaled prototypes for market decisions—Producing pouch cells up to 66 × 99 × 12 mm and 

7 Ah, large enough to make market decisions yet small enough to affordably demonstrate innovations

Unique Facilities

US Department of Energy (DOE) Battery Manufacturing Facility—Optimizing new materials and processes with 

scalable results at the nation’s largest open-access battery research facility

ORNL Grid Research Integration and Deployment Center—Simulating every aspect of the US power grid, 

including generation, energy storage for vehicles and the grid, transmission, and end used

DOE Spallation Neutron Source and High-Flux Isotope Reactor—Hosting two of the world’s most powerful 

neutron sources for nondestructive, atomic-level investigation of new materials

DOE Center for Nanophase Materials Science—Providing 

leading-edge tools and expertise for interdisciplinary research at the 

nanoscale

DOE Oak Ridge Leadership Computing Facility—Hosting 

the world’s first exascale and fastest supercomputer, Frontier, and 

one of the world’s leading supercomputers, Summit

DOE National Transportation Research Center—Accelerating 

development and deployment of advanced, efficient, and secure 

transportation technologies for a decarbonized energy future

DOE Manufacturing Demonstration Facility—

Driving the development of new materials, software, and 

systems for advanced manufacturing technologies for 

clean energy products

Comprehensive Capabilities 

www.ornl.gov/

content/batterymanufacturingfacility