Sakuu’s Dry-Printed Batteries Surpass 1,000 Cycles

Sakuu’s breakthrough in dry-printed lithium metal batteries marks a pivotal shift in electric vehicle (EV) battery design, combining high energy density with a dramatically lower carbon footprint. In a recent Munro team tour, Sakuu showcased how its innovative dry additive manufacturing process delivers batteries that not only exceed 1,000 charge cycles but also meet rigorous commercial and environmental standards. For automotive engineers, EV investors, and battery developers, this evolution signals a more sustainable, efficient future for energy storage.

From Slurry to Solvent-Free: Reinventing the Battery Electrode

Traditional lithium-ion batteries rely on wet-coating processes that use toxic solvents and energy-intensive drying ovens. These methods not only demand significant energy but also require sprawling facilities—often stretching up to 250 feet—to accommodate the full drying and solvent recovery systems. As a result, they generate substantial carbon emissions and incur high operational costs.

In contrast, Sakuu’s dry-printing process eliminates these steps entirely. Instead of using solvent-based slurries, Sakuu deposits dry powders directly onto foils through an advanced additive manufacturing technique. This streamlined approach removes the need for long drying ovens and hazardous solvent handling. The result is a dramatically more efficient system, capable of replacing bulky electrode lines with compact machines as short as 30 feet—delivering the same output with far less energy and environmental impact.

The result? A 55% reduction in process-level carbon emissions and a 40% reduction at the factory level. For EV OEMs and battery manufacturers striving toward carbon neutrality, this is a massive leap forward.

Achieving 1,000+ Cycles with Lithium Metal

While dry electrode processing is revolutionary, performance remains paramount. Sakuu’s lithium metal batteries demonstrate more than 1,100 cycles while maintaining 80% of their original capacity. These results, obtained with both conventionally and dry-processed cathodes, surpass the industry standard. Most lithium-metal cells struggle to exceed 400–700 cycles.

What’s more, the batteries meet or exceed all commercial benchmarks, including:

UN38.3 certification (essential for safe transport)
Voltage stability over calendar life
Resilience to overcharge and over-discharge
No dendrite formation, even under stress

Such performance makes Sakuu’s dry-printed lithium metal cells commercially viable—not just a lab curiosity.

Tailored Chemistry, Universal Platform

One of the most compelling aspects of Sakuu’s solution is its flexibility. The company doesn’t require proprietary materials. Instead, customers bring their own chemistries—be it high-energy cathodes or graphite/silicon anodes—and Sakuu adapts them to the dry-printing platform.

This two-step approach:

Pre-processes the customer’s powders to behave correctly in a dry format.
Prints high-quality, uniform layers using Sakuu’s proprietary method.

This method not only preserves the electrochemical properties but also delivers consistent thickness, density, and adhesion—key factors for long cycle life and energy performance.

Adhesion That Holds Up

Adhesion between the electrode layer and current collector is a critical challenge in dry processes. Sakuu addresses this with rigorous peel strength testing. Their dry-printed cathodes exhibit peel strengths around 2,000 gram-force—comparable to or better than wet-processed alternatives.

This ensures the electrode layer remains intact throughout its lifespan, enabling the long cycle life demonstrated in testing.

High-Power Performance: Fast Discharge, No Drop-Off

In addition to longevity, Sakuu’s batteries excel in power output. When subjected to aggressive discharge rates (as fast as 7 minutes), they retain 100% of their energy. This makes them ideal for applications requiring both endurance and rapid energy delivery—like EV acceleration or regenerative braking.

Test data confirms that even under high-rate cycling, the batteries maintain their capacity across 1,000+ cycles, an extremely rare feat in the lithium-metal space.

Application Spotlight: Sakuu’s Moto E-Bike

Sakuu’s in-house prototype electric motorcycle offers a real-world showcase of their technology. Designed in collaboration with renowned builder Walt Siegl, the Sakuu Moto integrates their battery pack in a sleek, lightweight frame.

The current version—powered by standard lithium-ion batteries—houses a 1.7 kWh pack. With Sakuu’s dry-printed lithium metal cells, the range increases by 40%, thanks to the superior energy density. When paired with the reduced weight and volume, this makes for a dramatically improved ride experience.

The Moto platform also serves as a modular testbed, letting Sakuu showcase future battery generations as they become production-ready.

Licensing, Not Manufacturing: Sakuu’s Business Model

Rather than competing with battery manufacturers, Sakuu is positioning itself as a technology licensor. The company provides:

Battery recipes
Prequalified materials
Validated equipment specs
Training and process IP

This means EV OEMs or battery startups can license Sakuu’s Cypress battery architecture or apply the dry-printing process to their own chemistries—scaling innovation without starting from scratch.

Sustainability in Every Layer

As EV adoption accelerates, sustainable manufacturing becomes just as important as clean driving. Sakuu’s dry-printed lithium metal batteries hit the sweet spot of:

Long life (1,100+ cycles)
High energy and power
Reduced carbon footprint
Scalable, solvent-free production

By eliminating solvents, reducing equipment footprints, and embracing flexible materials strategies, Sakuu is redefining what “green battery manufacturing” looks like.

Key Takeaways for Dry-Printed Lithium Metal Batteries

Additive manufacturing enables solvent-free electrode production, drastically cutting carbon and facility costs.
Lithium metal performance exceeds 1,000 cycles without dendrites—unmatched in the industry.
Dry-process electrodes match or surpass wet-processed benchmarks in adhesion, uniformity, and energy output.
Flexible platform lets manufacturers apply their own chemistries using Sakuu’s printing tech.
Licensable model means rapid adoption without new R&D from scratch.

Explore More from Munro

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