The research labs inside General Motors’ Global Technical Center in Warren, Michigan, are a far cry from what one might expect from a traditional car company. These top-secret facilities feature long, empty corridors illuminated with bright white lights, giving off a clinical and somewhat eerie vibe. The scientists working within these labs can be seen wearing full safety suits as they work on groundbreaking projects that are shaping the future of the automotive industry.
One of the key projects being developed at GM’s facility is the next-generation lithium manganese-rich (LMR) batteries that will power the company’s future electric vehicles. These batteries are being designed to provide improved performance, range, and efficiency for electric vehicles, setting the stage for a new era of sustainable transportation.
Not far from GM’s facility, Ford is also making strides in the development of LMR batteries at its Ion Park research hub in Romulus, Michigan. After four years of research and development, Ford recently announced a breakthrough in LMR battery chemistry and has begun pilot production in Michigan. This crucial step allows automakers to test and refine the batteries on a small scale before ramping up production for mass manufacturing.
The race to develop advanced battery technology is more important than ever, as American automakers seek to compete with China in the rapidly growing electric vehicle market. China has taken a significant lead in EV technology, leaving U.S. automakers to navigate unpredictable regulations, tariffs, and supply chain challenges. By developing cutting-edge LMR batteries, GM and Ford hope to level the playing field and establish themselves as leaders in the electric vehicle industry.
With the future of the automotive industry shifting towards electrification, U.S. automakers are investing heavily in research and development to stay ahead of the curve. GM and Ford are betting on LMR technology to drive their electric vehicle ambitions and propel them towards a sustainable and profitable future. By harnessing the power of advanced battery technology, these American automakers are poised to revolutionize the way we think about transportation and pave the way for a cleaner, greener future.
General Motors, in collaboration with LG Energy Solution, has developed a new chemistry for electric vehicle (EV) batteries that promises to reduce costs while maintaining range and performance. This breakthrough is expected to make EVs more accessible to a wider audience, helping to accelerate the transition to electric mobility.
InsideEVs had the opportunity to interview engineers from both companies to gain insight into the innovative Low-Cobalt Manganese-Rich (LMR) batteries and how they are overcoming engineering challenges to revolutionize the EV industry.
Welcome To General Motors’ Battery Kitchen
Creating EV batteries is a complex and challenging process that requires advanced technology and expertise. General Motors’ Kettering Research and Development lab, named after the renowned American inventor Charles Kettering, serves as a hub for material scientists working on cutting-edge battery technology.
The lab is equipped with state-of-the-art machinery used for synthesizing cathode materials, developing electrolytes, and testing battery components. Engineers liken the process to that of chefs in a restaurant, with each step carefully executed to ensure the highest quality battery cells.
From mixing electrode slurries to baking them into thin sheets, the meticulous process of battery production is akin to baking cookies, as described by one engineer. The attention to detail and precision required in each step is crucial to creating efficient and reliable EV batteries.
Once the cells meet the necessary standards, they are sent to the Wallace Battery Innovation Center for advanced testing and validation. This facility, named after battery development pioneer Bill Wallace, plays a vital role in ensuring the performance and durability of the batteries.
Getting Ahead Of China
General Motors has been dedicated to developing LMR cells for the past five years, starting from small coin cells to producing automotive-grade cells this year. While these cells are similar to the widely used nickel manganese cobalt (NMC) cells, they are expected to address cost challenges that have hindered battery production.
China currently dominates the global supply chain for raw materials essential in EV battery production, such as nickel and cobalt. With a significant share of battery cell production and refining capacity, China holds a strategic advantage in the EV market.
To counter China’s dominance, General Motors’ LMR batteries offer a promising solution by reducing the reliance on expensive nickel and cobalt. This shift towards more cost-effective lithium-iron phosphate (LFP) batteries could level the playing field and promote greater diversity in battery production.
The development of LMR batteries represents a significant step towards creating more sustainable and affordable EVs. By reducing costs without compromising performance, General Motors and LG Energy Solution are paving the way for a greener and more accessible future of transportation.
GM’s push towards using manganese in their batteries is a strategic move to reduce reliance on China for battery materials. Nickel and cobalt, which are traditionally used in batteries, are not only in high demand but also difficult and costly to mine and refine. Manganese, on the other hand, is more abundant, easier to process, and far less expensive, making it an attractive alternative.
In a bid to counter China’s dominance in the battery materials market, GM is transitioning from high-nickel batteries to lithium manganese-rich (LMR) batteries. These batteries have a lower nickel content and a higher manganese content, resulting in cost reduction. GM estimates that LMR cells will offer 33% more energy density than current LFP cells at comparable costs.
To support this transition, GM has invested $85 million in manganese supplier Element 25. This investment will enable the mining and processing of manganese in a “vertically integrated” and “traceable” manner from Australia. The processed materials will then be used to produce battery-grade manganese in the U.S., marking a significant step towards localization in battery production.
The LMR cells, when packaged in the prismatic form factor, are expected to have 50% fewer parts on the pack level compared to traditional cylindrical cells. This packaging design allows for neat stacking and fewer structural components, resulting in weight savings at the vehicle level. GM anticipates that the LMR battery will offer over 400 miles of range on their full-size SUVs and trucks.
Kurt Kelty, GM’s vice president of battery, propulsion, and sustainability, expressed confidence in the partnership with LG Energy Solution for the production of LMR batteries. The collaboration is set to drive innovation in battery technology and reduce dependence on costly and hard-to-source materials like nickel and cobalt. GM’s focus on manganese as a viable alternative highlights the importance of diversifying the battery materials supply chain for a more sustainable and resilient future. Ford will need to ensure that its LMR cells can be produced at a large scale without compromising on quality or performance. Poon acknowledged that this will be a challenge, but he expressed confidence in Ford’s ability to overcome it.
“We’re going to actually see this in the marketplace,” Poon said. “We’re moving full steam ahead with our LMR cells, and we’re excited about the potential they hold for the future of electric vehicles.”
Ford’s Ion Park facility in Romulus, Michigan is a key part of this effort. The state-of-the-art research and development center is where Ford’s team of battery engineers is working tirelessly to perfect the LMR technology. The facility serves as a hub for innovation, with engineers constantly pushing the boundaries of what is possible with battery technology.
With the announcement of GM’s own LMR ambitions, the race is on to see which company can bring this game-changing technology to market first. Both Ford and GM are investing heavily in LMR research and development, and the competition between the two automotive giants is sure to drive innovation in the electric vehicle industry.
As Ford continues to make strides with its LMR technology, consumers can look forward to a new generation of electric vehicles that offer improved range, performance, and affordability. The future of electric mobility is bright, and Ford is leading the charge with its innovative approach to battery technology. Stay tuned for more updates on Ford’s LMR cells as they make their way from the lab to the showroom floor. Ford had to overcome three major challenges before moving forward with the industrialization of their new battery technology. These challenges were identified by Poon, a key figure in the development process. The first challenge was the issue of “manganese dissolution,” where manganese tends to dissolve into the electrolyte over time, resulting in a gradual loss of energy and reduced range for the battery.
The second challenge was “gas generation,” which occurs as a result of manganese dissolution. Oxygen can react and produce gas inside the battery, leading to swelling or premature battery failure if not managed properly. Controlling this gas generation was crucial for ensuring the health and safety of the battery.
The third challenge was voltage. The LMR cells run at very high voltages, even higher than traditional NMC batteries. High voltage can accelerate wear and tear, so designing a battery that could safely handle the voltage without degrading quickly was essential.
Ford claims to have largely solved these challenges and is targeting an energy density between 550-700 watt hours per liter, or more than 200 watt hours per kilogram. This is comparable to current nickel-based batteries, which typically have an energy density of 200-300 Wh/kg.
Additionally, Ford’s LMR cells are said to be “agnostic to charging,” meaning they won’t inherently charge slower or faster. Depending on the vehicle segment and pack voltage architecture, charging speeds could match or even exceed current benchmarks. The choice of cathode chemistry (LFP, NMC, or LMR) doesn’t directly impact charging speed, as fast-charging primarily occurs on the anode side.
Ford is positioning its LMR technology to fill the gap between entry-level LFP batteries and high-end NMC models. Rather than replacing existing battery chemistries, LMR aims to enable automakers to target specific use cases in the U.S. market more effectively, with better packaging and cost efficiency. This also helps establish a more localized supply chain that is less reliant on China.
According to Poon, cost is a significant barrier to EV adoption, and Ford’s approach is not to introduce LMR technology for premium vehicles but to replace a significant portion of high-nickel and mid-nickel chemistries currently used. By doing so, Ford aims to make EV technology more accessible and cost-effective for a wider range of consumers.
In a race to the finish line, GM has announced its intention to become the first automaker to introduce LMR cells in a production truck by early 2028. Ford’s progress in overcoming key challenges and advancing their battery technology puts them in a strong position to compete in the rapidly evolving electric vehicle market. Now, with GM and Ford investing in the production of LMR cells in North America, the landscape of the electric vehicle market is set to change. The automakers are aiming to reduce costs, increase range, and improve the overall quality of their electric vehicles by localizing the battery supply chain.
GM, in partnership with LG Energy Solution, plans to scale the production of LMR cells within the next two years. This move comes as GM asserts its position as the largest producer of cells in North America. The automaker believes that it is now able to produce cells at a lower cost than its competitors in the region. While GM has not disclosed which truck will use the new LMR battery, the company’s commitment to expanding its electric vehicle lineup is evident.
Ford, on the other hand, also has plans to bring LMR cells to life by the end of the decade. With both GM and Ford investing in this technology, it is clear that LMR cells are poised to become a significant player in the electric vehicle market.
There are, however, reasons for caution. The technology has not yet been tested on the roads, and potential challenges may arise during the commercialization process. Despite these uncertainties, GM’s Vice President of Global Battery Cell Engineering, Tim Kelty, is confident in the future of LMR cells. Kelty highlights the importance of localizing the battery supply chain in order to produce competitive EVs.
Kelty draws from his experience at Tesla, where he witnessed the challenges of importing cells from overseas. By localizing battery production, automakers can avoid issues related to logistics and quality control. Kelty emphasizes that battery cells can sometimes have quality issues, which may only become apparent after weeks of inventory have been accumulated. By localizing production, automakers can address these quality issues more effectively and efficiently.
Ultimately, the move towards localizing battery production in North America represents a significant shift in the electric vehicle market. By investing in LMR cells, automakers like GM and Ford are positioning themselves to compete with Asian manufacturers who have historically led in battery innovation. As the electric vehicle market continues to evolve, the production of LMR cells in North America may prove to be a game-changer for the industry.