HUNTSVILLE, AL, USA, Dec 10, 2025 – Titomic Limited (ASX: TTT), a global leader in cold spray additive manufacturing utilizing their Titomic Kinetic Fusion technology, is pleased to announce a major advancement in the application of its Titomic Kinetic Fusion (TKF) for lithium-ion battery (LIB) electrode manufacturing.
Traditionally, LIB electrodes are manufactured using slurry-based processes that require multiple steps, including mixing, coating, drying, and calendaring. To overcome the limitations of this conventional approach, Rensselaer Polytechnic Institute (RPI), with support from the National Science Foundation (NSF) Energy Storage Engine in Upstate New York Program, has partnered with Titomic. RPI is partnering with Titomic in advancing cold spray–based dry-coating technologies aimed at enabling next-generation battery electrode manufacturing. Titomic’s cold-spray approach TKF™ eliminates the energy and time-intensive stages by directly depositing electrode powders onto aluminum or copper foils. This innovation can be seamlessly integrated into existing roll-to-roll production lines or adapted for 3D-printed electrodes with customized geometries and compositions.
The company’s technical program, in collaboration with Rensselaer Polytechnic Institute, is structured in four phases:
- Phase 1: Material Feasibility – Trials of candidate anode and cathode powders (such as silicon, LTO, LMO, and LFP) deposited onto foil substrates, with detailed micro- and macro-level characterization to determine spray parameters.
- Phase 2: Down-Selection & Demonstrator – Development of electrode demonstrators meeting industry requirements, including electrochemical testing for performance verification.
- Phase 3: Pilot TKF™ CS Station – Deployment of a pilot-scale system integrated with a customer’s LIB roll-to-roll manufacturing line.
- Phase 4: Detailed scalability and cost analysis to evaluate the transition from laboratory demonstrations to large-scale industry applications.
This approach addresses critical industry needs for more sustainable, efficient, and scalable electrode manufacturing. Beyond conventional graphite anodes, Titomic’s process enables advanced silicon–copper composite electrodes, which offer ultra-high theoretical capacity, and supports the development of all dry-coated (solvent-and binder-free) LIBs.
“This deposition breakthrough represents a pivotal moment in our expansion into the clean energy sector. By applying our proven TKF cold spray technology to battery electrode manufacturing, Titomic is helping to overcome long-standing efficiency and sustainability challenges in lithium-ion production. This development not only benefits our customers but also supports the global transition to renewable energy and electrification.” said, Jim Simpson, Titomic CEO and Managing Director.
“By directly depositing functional electrode materials via cold spray technology—without the need for binders, solvents, or drying steps—we are addressing critical inefficiencies in traditional slurry-based LIB production. Titomic’s dedicated cold spray systems enable direct and high-throughput deposition of LIB electrodes, helping to accelerate the transition toward renewable energy adoption and widespread electrification.” said, Prof. Semih Akin and Prof. Nikhil Koratkar, NSF project PIs from Rensselaer Polytechnic Institute.
Backed by more than a decade of cold spray expertise across aerospace, defense, and energy sectors, Titomic’s team is uniquely positioned to scale this innovation. With successful coatings and restoration projects delivered globally, Titomic is now leveraging its TKF™ 523 and TKF™ 623 platforms to deliver high-performance electrode deposition at industrial scale.
About Titomic Limited
Titomic Limited (ASX: TTT) is an Australian public company specializing in large integrated solutions for industrial- scale metal additive manufacturing, coating, and repairs using its patented kinetic fusion cold spray (Titomic Kinetic Fusion™) technology. Titomic Kinetic Fusion™ cold spray solutions provide OEM production and R&D services to the global Aerospace, Defense, Shipbuilding, Oil & Gas, Mining and Automotive industries. Titomic also offers global sales and support for all of its Titomic Kinetic Fusion™ cold spray AM activities from its Melbourne Head Office, as well as through local presence in the USA and Europe. Titomic delivers competitive advantages in metal additive manufacturing at every stage in the product value chain.
For more information, please contact Titomic via www.titomic.com.
