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Battery Trends of 2025: What’s Powering the Future of Energy?

Posted 22 Nov 2024 by Jessica Sundberg, Market Product Manager – ePower, Storage & Clean Energy

The electric vehicle (EV) revolution is well underway. In recent years, EVs have moved from niche market disruptors to mainstream transportation options, with global automakers making substantial investments in electrification. As the adoption of electric mobility accelerates, the focus is shifting from early-stage transformation to fine-tuning the technologies that will shape the next generation of batteries. As we near 2025, advancements in recycling, design, safety, and cell chemistry will not only enhance the efficiency and sustainability of EVs but will also redefine the boundaries of energy storage. Let’s explore the trends driving this ongoing shift.

Trend 1: Recycling and Re-use

With millions of EVs hitting the road, attention is shifting toward what happens when these vehicles reach the end of their life cycle. Sustainability has become a focal point, and recycling is set to be one of the biggest growth areas in battery technology.

  • Re-use Enabled by Debond on Demand

    A key innovation in battery recycling is "debond on demand" technology. This cutting-edge solution allows manufacturers to disassemble battery packs with minimal effort. Adhesives, which bond cells together, can be reversed when required using various trigger methods, making it easier to separate and recycle materials. Once cells are de-bonded, they can be repurposed into other applications such as battery energy storage systems (BESS). This reduces both energy and waste in the recycling process, allowing for a more sustainable, circular economy.

  • Sustainability

    Battery manufacturers are demanding more sustainable practices from their suppliers, pushing for eco-friendly sourcing and production methods. Suppliers are now required to adopt cleaner extraction processes for key materials like lithium and cobalt, minimizing environmental harm. Additionally, there’s growing interest in bio-based materials as alternatives to traditional petroleum-based components. These renewable resources are being used in everything from binders to electrolytes, offering a greener approach. 

  • Repurposing Raw Materials

    In addition to recycling for new batteries, there’s growing interest in repurposing valuable raw materials from spent batteries for other industries. Metals like lithium, cobalt, and nickel can be extracted from used battery cells and repurposed in a variety of applications, from electronics and renewable energy systems to aerospace components. This approach not only reduces the demand for freshly mined materials but also supports a more diversified and resilient supply chain. By 2025, we expect to see these repurposing practices gaining momentum, further reinforcing the sustainability loop and expanding the value proposition of battery recycling beyond just energy storage.

Trend 2: Cell-to-Pack and Cell-to-Chassis Designs

The design of battery packs is becoming more efficient and streamlined, and two innovations—cell-to-pack and cell-to-chassis—are leading this charge.

  • Cheaper Packs and Lower Weight

    Traditionally, batteries were built by assembling individual cells into modules, which were then combined to form a battery pack. But cell-to-pack designs remove the modular layer, packing cells directly into the larger battery unit. This reduces the overall weight and cost of production. Without the additional module structure, manufacturers can build lighter and more compact batteries.

  • Higher Energy Density

    Cell-to-chassis designs go even further, integrating the battery directly into the vehicle’s structure. This saves space and weight, leading to higher energy density and improved vehicle range. The increased efficiency makes electric vehicles more cost-effective and appealing to consumers, further accelerating EV adoption.

Trend 3: Battery Pack Safety

As batteries get more powerful, safety is becoming a top priority. The thermal management of battery packs is under constant improvement to prevent overheating, thermal runaway and dangerous battery fires.

We can expect to see more advanced monitoring systems embedded into battery packs, capable of detecting and neutralizing potential hazards before they escalate. Innovations such as fire-retardant adhesives, thermal barriers, and improved cooling systems will play a vital role in ensuring that battery packs remain safe even under extreme conditions.

  • Materials Innovation

    The push for improved battery safety is driving significant materials innovation. Advanced materials are being developed to enhance the thermal stability and fire resistance of battery packs. For example, new fire-retardant adhesives and intumescent coatings expand and create a protective barrier when exposed to high temperatures, helping to prevent fires from spreading within battery packs. These innovations not only protect against overheating and thermal runaway but also contribute to the overall longevity and efficiency of battery packs.

  • Regulatory Action

    As battery technology advances, regulatory bodies worldwide are enforcing stricter safety standards. For example, the United Nations Manual of Tests and Criteria, Part III, Subsection 38.3 sets global safety testing protocols for lithium batteries. These tests evaluate the battery's resistance to conditions like extreme temperature, shock, and impact to prevent risks during shipping. In Europe, the EU Battery Directive (currently being revised) includes new provisions to address battery safety, mandating more rigorous lifecycle assessments and fire resistance testing for all batteries sold in the EU. Additionally, under UN Regulation No. 100, battery packs in electric vehicles must undergo crash safety tests and thermal propagation tests, ensuring that individual cell failures do not lead to catastrophic thermal events across the entire pack.

In the United States, the National Highway Traffic Safety Administration (NHTSA) is also developing new standards to improve EV battery safety, with a focus on crashworthiness and thermal runaway prevention. The SAE J2464 standard is another key regulation that outlines abuse testing for batteries, requiring them to withstand extreme conditions like overcharging, short-circuiting, and fire exposure without failure. These regulatory actions are driving manufacturers to prioritize safety innovations across the entire battery lifecycle. 

Trend 4: Cell Chemistry Beyond Lithium-Ion

While lithium-ion batteries currently dominate the EV market, as we step into the future, we will witness the rise of alternative chemistries that promise to revolutionize energy storage.

  • Solid-State Batteries

    Solid-state batteries are one of the most anticipated breakthroughs. These batteries replace the liquid electrolyte with a solid material, which enhances safety and energy density. Solid-state technology allows for faster charging, higher capacity, and longer battery life. Although commercial applications of solid-state batteries have been slow to roll out, advancements by 2025 could push this technology into mainstream use, particularly in high-performance EVs.

  • Beyond Lithium

    Alongside solid-state batteries, chemistries such as sodium-ion and lithium-sulfur are gaining traction. These alternatives are attractive due to their abundance and potential for higher energy densities at lower costs.  With supply limitations due to geographic concentration, extraction challenges, and increasing demand, alternate chemistries may offer a path to more scalable, sustainable battery production.

Trend 5: Faster Charging

One of the main pain points for EV owners is charging time. But as technology advances, charging speeds are set to improve dramatically by 2025.

We are already seeing a shift toward higher voltage battery systems—800V systems are becoming more common, compared to the traditional 400V systems. Higher voltage levels enable faster charging times without compromising battery health. As infrastructure continues to evolve, fast-charging stations capable of delivering full charges in mere minutes could become the new norm, significantly enhancing the appeal of EVs.

Trend 6: Changing Regulatory Landscape

Government regulations are shaping the future of battery technologies as well, with a focus on sustainability, safety, and performance. By 2025, regulatory frameworks will likely impose stricter standards on battery production, recycling, and end-of-life management.

The European Union’s Battery Directive now includes stricter recycling quotas and sourcing transparency requirements. In China, new regulations are aimed at improving battery traceability and environmental impact, while the U.S. government is introducing incentives to boost domestic battery production through the Inflation Reduction Act. By 2025, these regulations will push the industry toward greener, safer batteries, with stricter oversight across manufacturing, transportation, and recycling worldwide.

The Future of Energy

Throughout 2025, the battery industry will continue to evolve in response to technological advancements, consumer demands, and regulatory pressures. From recycling innovations and new cell designs to faster charging and safer packs, the future of energy storage is bright. These trends will not only shape the electric vehicle landscape but also power a more sustainable, electrified world.

As batteries become more powerful, affordable, and sustainable, they will play an even larger role in the global transition toward clean energy, driving forward the future of mobility and renewable energy storage.

Our team at H.B. Fuller is passionate about creating a greener future and helping our customers navigate these changes. To learn about our products or connect with a member of our team, reach out to [email protected].

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