Swiss researchers at the Paul Scherrer Institute PSI have developed a new production process that extends solid-state battery lifespan to 1,500 cycles with 75% capacity retention. The breakthrough, published in Advanced Science this month, addresses two critical barriers to market-ready solid-state batteries.
The team led by Mario El Kazzi combined gentle sintering at 80°C with a 65-nanometer lithium fluoride coating. This dual approach suppresses lithium dendrite formation and stabilizes the anode-electrolyte interface, solving persistent safety and performance issues.
Laboratory tests with button cells demonstrated remarkable cycle stability under high voltage conditions. "These values are among the best reported to date," said doctoral candidate Jinsong Zhang, lead author of the study. The process uses argyrodite-type LPSCl solid electrolyte compressed under moderate pressure.
Separately, South Korean researchers announced a structural design breakthrough on January 7 that improves solid-state battery performance without expensive metals. The KAIST-led team developed a Framework Regulation Mechanism using divalent anions like oxygen and sulfur to reshape ion pathways.
Professor Dong-Hwa Seo's team achieved ionic conductivity of 1.78 mS/cm with oxygen-doped zirconium-based electrolytes, nearly double traditional performance. Their approach focuses on crystal structure modification rather than material substitution, reducing production costs while maintaining safety advantages.
Both developments target the same core challenge: improving lithium-ion mobility through solid electrolytes. Conventional lithium-ion batteries use liquid electrolytes that pose fire risks, while solid-state alternatives offer inherent safety but struggle with ion transport efficiency.
The Swiss method's gentle 80°C processing temperature offers ecological and economic advantages over traditional 400°C sintering. "Our approach is a practical solution for industrial production," said El Kazzi. "A few more adjustments and we could get started."
Solid-state batteries promise higher energy density, faster charging, and improved safety for electric vehicles and mobile electronics like the Honor Magic 8 Pro. The dual breakthroughs from Switzerland and South Korea represent complementary approaches to commercialization hurdles that have delayed widespread adoption.
Industry analysts note that successful solid-state battery deployment could extend electric vehicle ranges by 30-50% while eliminating thermal runaway risks. Major automakers including Toyota, Volkswagen, and BMW have invested billions in solid-state research partnerships.
The Swiss research demonstrates exceptional durability with 1,500 charge cycles maintaining three-quarters of original capacity. This longevity exceeds many current lithium-ion batteries while operating at higher voltages suitable for rapid charging applications.
South Korea's structural design innovation reduces reliance on costly rare earth metals, addressing manufacturing scalability concerns. The team's work, published in Nature Communications in November 2025, received funding from Samsung Electronics and national research foundations.
Both research groups emphasize practical manufacturability alongside performance improvements. The combined advances could potentially accelerate solid-state battery commercialization timelines.
Market projections indicate solid-state battery adoption could reach $8 billion annually by 2031, driven primarily by electric vehicle demand. Current limitations around production costs and cycle life appear increasingly solvable through these parallel research pathways.
The simultaneous breakthroughs from Europe and Asia highlight global competition in next-generation battery technology. With China dominating current lithium-ion production, Western and Korean researchers are racing to establish leadership in the solid-state transition.
Technical challenges remain around large-scale electrode fabrication and thermal management, but the core electrolyte and interface problems show promising solutions. Some industry analysts suggest pilot production lines could emerge within the next few years based on these research outcomes.
Consumer electronics manufacturers may adopt solid-state batteries first due to lower volume requirements and premium pricing tolerance. Devices like Apple's upcoming iPad mini with the 2nm A20 Pro chip could benefit from these longer-lasting batteries. Electric vehicle integration will follow as production scales and cost curves improve through manufacturing innovations.
The research represents significant progress toward batteries that store more energy, charge faster, and operate safer than conventional lithium-ion technology. With multiple viable pathways emerging, the solid-state battery revolution appears increasingly imminent rather than speculative.
