A pilot project involving Lucideon's pioneering Flash Sintering technology has delivered a step-change in the process of manufacturing a type of battery that reduces the demands on earth's scarce resources
The project, undertaken by a consortium led by Batri Limited and including Swansea University's Energy Storage Group, overseen by Professor Serena Margadonna, has delivered significant scale-up and sustainability benefits by working together.
While lithium-ion technology currently dominates the battery landscape, the method of manufacture demands huge amounts of water, energy and the critical raw material lithium.
Sodium-ion batteries offer an attractive alternative due to the fact they are made using more abundant and locally sourced raw materials, predominantly sodium and carbon, as well as offering the flexibility of use across a wide range of applications and better recyclability characteristics.
Under the programme, scientists, engineers, and academics have pioneered a novel way to make the manufacture of sodium ion battery materials faster and more sustainable as part of a twelve-month feasibility project supported by UKRI's £318 million Faraday battery challenge fund.
The fund supports the UK's use of technology to become a global leader in low energy and low waste manufacturing methods.
Under the programme, the three partners have delivered significant scale-up and sustainability benefits by working together to deploy the use of Flash Sintering, an advanced technology that involves the application of an electric field to a material via customized electrodes to achieve a concise, high temperature heating rate with pinpoint accuracy.
This approach reduces the amount of energy needed, with the heat directly targeted at the material being processed.
Dr Gareth Jones, Lucideon's Flash Sintering Technical Lead, said: "This is an exciting project, which has brought together Lucideon's Flash Sintering expertise with the knowledge of Batri, a pioneering developer of sodium-ion electrode materials, and Swansea University's Energy Storage Group, which is at the forefront of sodium-ion battery technology.
"Together we have created an energy-efficient process for Batri's innovative electrode chemistry, which could prove to be a key step in positioning sodium-ion technology as a flexible and sustainable solution for energy storage challenges across multiple industries.
"The results showed that sodium-ion battery cathode material processing can be carried out at lower furnace temperatures and more quickly.
"Material was able to be manufactured in furnace temperatures several hundred degrees Celsius lower than standard processing, leading to 80 per cent reductions in cycle time and process energy consumption.
“And as we scaled-up the process, we were able to significantly increase the amount of powder processed in one run."
Dr Jones says future work is now needed to fine tune the process to achieve further energy saving outcomes and increase the volumes of powder synthesized.
He added: "Working with Batri and Swansea University has shown that enhanced synthesis of battery electrode materials is an exciting new application for our Flash Sintering technology.
"This represents a significant advance in reducing the use of resources and energy efficiency, which could be key to driving the growth of a strong business in the UK.
"We now look forward not only to developing the approach into a production process but also identifying other applications that would benefit from faster and lower temperature processing of powders."
Dr Stephen Hughes, CTO at Batri, said: "The success of this project reflects the outstanding collaboration between all partners.
"Sodium-ion cells have already established themselves as a viable alternative to lithium-ion technology across a growing range of applications.
"Batri's advanced materials are key to unlocking the full potential of this technology, enabling the use of locally sourced resources, low-impact manufacturing processes, and securing sovereign control of critical IP.
"The innovations delivered through this programme show how Batri and its partners are helping position the UK as a global leader in next-generation energy storage solutions."
» Read about Lucideon's Flash Sintering technology
About Batri
Batri is reshaping what's possible in clean energy through its pioneering sodium-ion battery materials and cells.
Empowered by a decade of research and a strong IP foundation, Batri delivers net-zero solutions that serve diverse applications, from green mobility to next-generation power systems.
About The Energy Storage Group at Swansea University
The Energy Storage Group at Swansea University is a leading research team in electrochemical energy storage and advanced materials engineering.
Dedicated to accelerating the transition to cleaner, more resilient energy systems, the group develops next-generation battery technologies through a unique integration of materials innovation, cell prototyping, and in situ characterization.
With a strong focus on real-world impact, the Energy Storage Group collaborates across academia and industry to create high-performance, sustainable storage solutions. Its expertise spans sodium-ion, lithium-ion, and emerging battery chemistries, addressing key challenges in cycle life, cost, and materials sustainability.
Supported by state-of-the-art facilities - including laboratories for materials synthesis, multi-format cell assembly (coin, pouch, and cylindrical), and advanced characterization techniques - the group offers comprehensive capabilities from fundamental discovery to near-industrial validation.
Through strategic partnerships and a proven track record in securing competitive funding, the Energy Storage Group plays a vital role in shaping the UK’s energy innovation landscape.
June 2025