The solid-state battery (SSB) market is undergoing significant changes, with its global value projected to soar from $1.60 billion in 2025 to an impressive $15.65 billion by 2033.
A huge turning point for the tech came at CES 2026 when Donut Lab announced their new solid-state batteries are finally ready for major OEM production. This milestone marks a pivotal moment: solid-state technologies are moving beyond laboratory prototypes toward commercial scalability.
The shift of solid-state technologies from lab prototypes to scalable production presents battery developers with a clear hurdle: the need for understanding, process control, and validation of materials at every stage of growth.
Dr Umesh Tiwari, Market Development Manager at Malvern Panalytical, explains how advanced material characterisation can accelerate the development of next-generation batteries.
Demand solid-state battery optimisation
Industry focus has shifted: rather than ‘if’, businesses are now asking ‘how quickly’ can all-solid-state batteries be mass adopted. These batteries boast a 400Wh/kg energy density, ultra-fast charging (under 5 minutes), extreme safety, 100,000-cycle durability, and consistent performance across a range of temperatures.
However, optimisation is required to overcome current SSB limitations. These include enhancing ionic conductivity, improving the contact at the electrode-electrolyte interface, and enabling the use of high-capacity lithium metal anodes. Core strategies involve developing advanced solid electrolytes, such as sulfide or oxide-based materials, and designing engineered composite cathodes. Additionally, advanced manufacturing techniques like dry coating are crucial for reducing interfacial resistance and improving the battery’s overall volumetric stability and longevity.
Another area to optimise solid-state batteries is via the demand for safe and efficient energy storage solutions, which has spurred the proliferation of new battery technologies. SSB represent a significant leap forward, poised to overcome major limitations associated with conventional lithium-ion batteries (LIBs).
The incorporation of a solid electrolyte is key to mitigating several risks inherent in liquid electrolyte-based batteries. These risks include high flammability, dendrite formation, electrolytic decomposition at high voltages, and leaks.
Rheology: the key to optimisation
As the market accelerates, many companies are at a crucial development juncture. For instance, a solid-state “Donut Battery” has demonstrated superior charge retention, holding 97.7% of its capacity after 10 days of inactivity.
Central to this evolution is advanced powder rheology, which ensures the quality, safety, and efficacy of solid-state battery components. Electrode manufacturing requires ensuring the precise dispersion of active materials and predictable behaviour upon processing. Particle size, droplet distribution, and formulation stability all play critical roles.
Controlling particle size, morphology, porosity, density, crystalline structure, and surface area is vital for achieving optimal ionic conductivity, proper densification, stable interfacial properties, high performance, and long cycling durability. To gain rapid, reproducible insights from the R&D stage through to pilot scale, techniques such as laser diffraction, X-ray diffraction (XRD), BET surface area analysis, and porosity analysis are indispensable tools.
Performance, safety & lifetime
Optimising solid-state battery performance—specifically cycle life, fast charging, and thermal robustness—relies fundamentally on a deep understanding of microstructure, pore architecture, and interfacial contact.
Employing advanced materials characterisation techniques, such as X-ray Diffraction (XRD), allows manufacturers to de-risk scale-up processes and avoid costly production missteps.
Additionally, research shows that solid-state batteries with lithium metal anodes have the potential for higher energy density, longer lifetime, wider operating temperature, and increased safety.
Dr. Umesh Tiwari, Market Development Manager at Malvern Panalytical, says, “The challenge for battery developers becomes clear: understanding, process control, and validation of materials at every stage of growth. The transition to solid-state batteries necessitates a fundamental shift in material characterisation and process control.
“Success will be defined by the ability to accurately measure, deeply understand, and rigorously control the properties of new solid-state materials—from initial research and development through to high-volume manufacturing scale-up. Another essential challenge will be sustainability and safety when it comes to solid-state batteries. The powder rheology will play a crucial role in ensuring efficient production, which ensures the quality, safety, and efficacy of solid-state battery components.”
