Scientists have developed a new technology that could make electric car batteries smaller, lighter and longer-lasting, potentially letting drivers travel farther on a single charge without carrying a heavier battery

NewsScience NewsScientists have developed a new technology that could make electric car batteries smaller, lighter and longer-lasting, potentially letting drivers travel farther on a single charge without carrying a heavier battery Scientists have developed a new technology that could make electric car batteries smaller, lighter and longer-lasting, potentially letting drivers travel farther on a single charge without carrying a heavier battery TOI Lifestyle Desk / TIMESOFINDIA.COM / Nov 02, 2026, 03:50 IST Every day we look at the rise of EVs and climate concerns and think about shifting to electric vehicles.

But one of the biggest concerns people have when buying an electric car is its driving range. While manufacturers are constantly working to improve battery performance, making batteries larger is not always the best solution, especially when it adds more weight to the vehicle.

But what if electric cars could travel farther without carrying bigger and heavier batteries? Scientists may have found a way to make this possible by rethinking how batteries are designed.Researchers from the Korea Advanced Institute of Science and Technology (KAIST) have developed a new technology that could make electric vehicle batteries smaller, lighter and longer-lasting.

The team has found a way to address one of the biggest problems with anode-free batteries, a next-generation design that removes conventional materials such as graphite to make more room for energy storage. The findings were published in the journal Advanced Functional Materials.Why are scientists working on anode-free batteries?

In conventional lithium-ion batteries, lithium is stored in a component called the anode, which is generally made using graphite. However, anode-free batteries work differently. Instead of using a separate anode material, lithium accumulates directly on a thin copper sheet when the battery is charged.By removing the conventional anode, manufacturers can potentially reduce the battery's weight and thickness while storing more energy in the same amount of space.

This could eventually allow electric vehicles to travel longer distances without requiring larger battery packs.However, there is one major problem. During repeated charging and discharging, lithium does not always spread evenly across the copper surface.

Instead, it can form sharp, needle-like structures known as dendrites. These structures can damage the battery and interfere with its performance, while an unstable protective layer around the lithium can further accelerate its deterioration.How did researchers solve the problem?

To address this issue, the researchers redesigned the copper surface where lithium accumulates. Using a manufacturing technique borrowed from the semiconductor industry, known as secondary sputtering lithography, they created microscopic tube-like structures across the copper foil.Each of these tiny structures measures approximately 300 nanometres in diameter and 150 nanometres in height.

Together, they increase the available surface area for lithium deposition to around four times that of an ordinary flat copper sheet. This provides more space for lithium to settle evenly instead of accumulating in concentrated areas and forming damaging spikes.The researchers also applied an extremely thin coating of MXene, a two-dimensional material, measuring approximately 10 nanometres in thickness.

Rather than acting as a protective layer itself, the coating encourages the formation of a stable protective layer rich in lithium fluoride as the battery operates.This layer helps reduce unwanted chemical reactions between lithium and the electrolyte while also limiting the growth of damaging lithium structures.Could this change the future of electric cars?

According to the researchers, the new approach could help overcome one of the major obstacles preventing anode-free batteries from becoming commercially viable. By improving the stability of lithium deposition without adding excess materials, the technology could help preserve the advantages of these batteries, particularly their reduced weight and size.Professor Jinwoo Lee, who led the research alongside Professor Hee-Tae Jung, said the study demonstrates how precise manufacturing techniques used in semiconductor production can create uniform sites for lithium deposition and a stable protective layer without adding excess lithium or changing the bulk electrolyte formulation.Although the findings are promising, further development and testing will be needed before the technology can be used in commercial electric vehicles.

Still, the research offers a possible route towards batteries that take up less space, weigh less, and potentially allow electric cars to travel farther on a single charge.This is not only a good sign technologically but also towards a good cause for our climate.

Many people who miss out on EVs because of this issue could be encouraged to make the switch, potentially giving a boost to EV sales. The TOI Lifestyle Desk is a dynamic team of dedicated journalists who, with unwavering passion and commitment, sift through the pulse of the nation to curate a vibrant tapestry of lifestyle news for The Times of India readers.

At the TOI Lifestyle Desk, we go beyond the obvious, delving into the extraordinary. Consider us your lifestyle companion, providing a daily dose of inspiration and information. Whether you're seeking the latest fashion trends, travel escapades, culinary delights, or wellness tips, the TOI Lifestyle Desk is your one-stop destination for an enriching lifestyle experience.

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