American innovation promises 50 percent longer range for electric vehicles

Massachusetts-based 24M Technologies has unveiled a new ETOP (Electrode-to-Pack) battery design that promises up to 50 percent more range for electric vehicles without increasing the size of the battery. The key innovation is that the electrodes are sealed in a thin polymer film and directly integrated into the battery pack.

This approach abandons the traditional manufacturing of batteries from individual cells, which contain a lot of inactive materials such as metals and plastics. According to 24M, ETOP technology can increase the proportion of electrodes in a battery to 80 percent, compared to 30 to 60 percent in conventional batteries.

The technology is compatible with a variety of chemistries, including NMC, LFP, NCA and sodium batteries. In addition to higher energy density, it also allows for greater design flexibility, allowing batteries to be shaped to fit the space in a vehicle. ETOP batteries are cheaper to manufacture, eliminating the need for many components such as metal containers and connectors. 24M claims that the technology is ready for production, with the first prototypes already in the testing phase.

Due to its similarity to current battery structures, only a modest investment in production lines is required. The company expects to start production in 2027, with commercial use expected to follow after 2028. In addition to the automotive industry, 24M is also working with aviation, e-mobility and energy companies, where ETOP could gain traction even faster.