By replacing heavy metals with carbon fiber, this could extend EV ranges by 70% and revolutionize the aerospace industry.
Researchers from Chalmers University of Technology are presenting new data on structural battery composites at the World Economic Forum. Called the “world’s strongest,” this battery was previously identified as the top emerging technology of 2025 by the forum.
The latest findings indicate that these materials have reached a performance level where they can function as both energy storage units and primary structural components in industrial applications.Structural batteries are engineered to carry mechanical loads while simultaneously storing electrical energy. This dual functionality allows the battery to serve as the actual frame or housing of a product, effectively removing the need for a separate, heavy battery pack. According to the research team led by Professor Leif Asp and Assistant Professor Johanna Xu, the newest iteration of this material demonstrates multifunctional properties that approach the energy density of traditional lithium-ion batteries and the mechanical stiffness of metals such as aluminum and titanium.Design eliminates use of heavy metalsThe material architecture is based on a composite that utilizes carbon fiber for both the positive and negative electrodes. “In the anode it acts as reinforcement, as well as an electrical collector and active material. In the cathode it acts as a reinforcement, current collector, and as a scaffolding for the lithium iron phosphate to build on,” said the university in a press release.By utilizing the natural electrical conductivity of carbon fiber, the design eliminates the requirement for heavy metal current collectors typically made of copper or aluminum, which further reduces the total weight of the system.In contrast to conventional batteries that use liquid electrolytes, this structural battery employs a semi-solid electrolyte. This choice of material helps transport lithium ions between terminals while increasing the overall safety of the cell by lowering the risk of thermal runaway and fire. While the researchers acknowledge that further work is required to increase the power output to match high-demand industrial needs, the current results suggest the technology is ready for significant industry investment.Improving electrified transport systemsThe implications for weight reduction are substantial across multiple sectors. In consumer electronics, this technology could lead to laptops that weigh half as much as current models or mobile phones with significantly thinner profiles. For transport, immediate applications are expected in the production of drones and handheld tools. In the long term, the material is intended for use in the automotive and aerospace industries, where it could be integrated into vehicle chassis or aircraft fuselages to improve energy efficiency.“We have made calculations on electric cars that show that they could drive for up to 70 percent longer than today if they had competitive structural batteries,” Professor Asp had stated earlier. He concluded that the development of safety regulations and standards will be a necessary step for the widespread adoption of structural battery composites. If these frameworks are established, the technology is expected to provide measurable environmental and economic benefits by reducing material consumption and improving the range and efficiency of electrified transport systems.
Electric Vehicle (EV) Energy &Amp Environment Lithium-Ion (Li) Battery
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