A Fraunhofer team is replacing most of the liquid electrolyte with solid materials to create a safer, more stable solid-state lithium-sulfur battery with higher energy density and the potential for longer range and lower costs.

Researchers at the Fraunhofer Institute for Material and Beam Technology in Dresden have developed a next-generation solid-state Li-S battery designed to overcome long-standing barriers to commercial viability.

Two major funding initiatives support the work—AnSiLiS from Germany’s Federal Ministry of Research, Technology, and Space and TALISSMAN from the EU’s Horizon Europe program—both aimed at stabilizing Li-S chemistry to prevent performance loss over time.

Li-S batteries offer theoretical energy densities up to double those of conventional lithium-ion and use sulfur, an abundant and inexpensive material, though they have historically faced degradation from polysulfide byproducts in liquid electrolytes.

Early lab results indicate energy densities above 600 Wh/kg, with commercial targets around 550 Wh/kg and costs below $86 per kWh, potentially reducing EV ownership costs and enabling longer-range models.

Production benefits include the DRYtraec solvent-free coating method, which can reduce production energy use by up to 30% and cut CO2 emissions, while remaining compatible with existing lithium-ion production lines to aid adoption by automakers.

If scaling continues as hoped, the technology could power not only electric cars but also drones, aircraft, and portable devices, with full prototypes anticipated in coming years.

The new battery design could enable lighter, faster-charging vehicles that ease grid demand while maintaining zero tailpipe emissions and improving urban air quality.