Advanced Manufacturing Technologies

Big Delta Systems (BDS) is commercializing an advanced, additive manufacturing technology for the production of superior Li-ion battery electrodes that push the performance envelope of todays batteries while significantly reducing costs. This additive manufacturing technology offers an unprecedented design freedom for battery manufacturers to micro-engineer the structure of electrodes optimized for cost and performance. For this Advanced Manufacturing Technologies solicitation from the Defense Logistics Agency (DLA), BDS will develop advanced battery electrode prototypes based on its additive manufacturing technology, demonstrating the ability to make ultra-thick cathode electrode coatings featuring porosity gradients using various Li-ion electrode materials of specific interest to the military. The combination of ultra-thick electrodes with porosity gradients enables batteries with significantly improved energy densities without compromising power performance. These performance enhancements, coupled with the increased manufacturing production speeds versus state-of-art, ultimately results in reduced bill-of-materials costs, reduced overall battery pack costs, reduced number and weight of battery packs for soldiers to carry, and reduced transportation and disposal costs to the military. Cumulative cost savings to the DLA will be substantial. Performance improvements benefiting the Warfighter will also be significant. BDS is already engaging with multiple battery manufacturing suppliers to the DLA to accelerate its rapid commercialization efforts.