Dragonfly Energy
Dragonfly Energy's dry electrode battery manufacturing process validates as more sustainable and cost-effective than conventional methods

Dragonfly Energy’s domestic battery manufacturing validated for cost-effectiveness and sustainability

April 12, 2024
A cost and sustainability assessment concludes Dragonfly Energy’s patented dry electrode battery manufacturing process is scalable, more cost-effective, and more sustainable than the current technology.

Dragonfly Energy, a manufacturer of deep cycle lithium-ion batteries, has announced the results of an Energy Cost & Sustainability Assessment conducted by Sphere Energy, a global battery testing and advisory firm. The assessment highlights significant cost and sustainability improvements made by Dragonfly Energy’s patented dry electrode battery manufacturing process when compared to the state-of-the-art production process currently employed by conventional battery-cell manufacturers. Results and findings presented were based on specific data from Dragonfly Energy’s cell manufacturing pilot line located in Northern Nevada.

The assessment concluded that Dragonfly Energy’s dry electrode battery manufacturing process resulted in a 9% reduction in carbon footprint for cell manufacturing without toxic NMP solvents, making it more sustainable. In addition, with Dragonfly Energy's process (spray drying, coating, calendaring), energy usage during electrode manufacturing is reduced by 71% compared to standard cell manufacturing (slurry casting, drying, calendaring).

Dragonfly Energy's manufacturing process uses 22% less square footage by eliminating the need for large, expensive drying ovens. As a result, emissions from energy use are reduced by 25%, making the process more sustainable and environmentally friendly.

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Additionally, Dragonfly Energy’s process was found to be cost-effective, saving an estimated 5% (depending on cell chemistry) on process-related costs over conventional methods. The savings were calculated without the additional cost benefits provided by domestically manufactured battery cells, such as IRA tax credits, tariffs, and shipping.

“The findings from the Sphere Energy Cost & Sustainability Assessment support expectations that our innovative dry electrode process results in significant energy and cost efficiencies while promoting environmental sustainability,” said Dr. Denis Phares, CEO of Dragonfly Energy.

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FleetOwner Staff

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