Advanced Manufacturing Technologies

This Phase II Small Business Innovation Research project develops the scale of lithium-ion direct recycling technologies applied to gain efficiencies in materials management from original manufacturing to end-of-life. The scrap materials are from Defense Logistics Agency manufacturing activities. A successful effort moves direct recycle TRL from 4 to 6, increases process throughput, qualifies material for re-use in manufacturing for DLA applications, and outlines a cost savings of 30% for batteries built with reclaimed material. The Phase I program demonstrated direct recycling of new lithium-ion formulations, returning full capacity and performance to battery materials worn to 80% of their original capacity. The process model shows the capability of producing lithium-ion electrode materials for 30% of the cost of competitive material. These technologies implemented into a future service will address DLA Advanced Manufacturing Technologies Objectives for "improved business methods" through reuse of critical materials, and "affordability and advanced industrial practices" with low cost electrodes from reclaimed materials. The successful development and implementation to a business service impacts lithium-ion manufacturing with the reduction and elimination of end-of-life disposal fees, and 30% reduction in the cost of advanced cathode materials.