Tag Archive: battery technology

  1. In-depth investigation exposes Donut Lab’s solid-state battery as regular li-ion

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    Source: Electrek Image source: Electrek

    Following a high-profile reveal in January at CES 2026 of a solid-state battery for electric motorcycles, the claims made by Donut Lab have been thoroughly investigated by science and engineering channel Ziroth. With input from over 20 independent battery experts, the investigation concludes with what amounts to definitive proof that the battery is in fact a lithium-ion cell.

    Doubts about the veracity of the claims by Donut Lab – 400 Wh/kg, 100,000 charging cycles, and 5-minute charging – about the solid-state battery have been circulating for some time. A whistleblower complaint was made in April by Lauri Peltola, the former CCO of Nordic Nano, the manufacturing partner of Donut Lab. This complaint accused Donut Lab of “misleading the public with its claims, specifically on energy density, durability and production capacity.”

    At an even earlier stage, Electrek’s Editor-in-Chief, Fred Lambert, interviewed Donut Lab CEO Marko Lehtimäki soon after the CES 2026 announcement, with a great deal of scepticism about the claims.

    Independent testing from Finland’s VTT Technical Research Centre could not support the 400 Wh/kg energy density and 100,000-cycle life claims. Donut Lab undertook its own Technical Due Diligence (TDD) process, rather than seeking independent validation – a process described by Lauri Peltola as deeply inadequate, given the lack of battery chemistry expertise.

    The companies behind the battery

    The Ziroth investigation uncovers the relationship of companies behind the battery – none of which have specialised battery expertise. Donut Lab was created as a spin-off of the Finnish electric motorcycle brand, Verge Motorcycles. CT Coatings, a German company, was the technology provider; Nordic Nano the manufacturer; and Donut Lab the commercialiser. However, CT Coatings promised a screen-printed sodium-ion solid-state battery, but what it delivered was a lithium-ion pouch cell. It is also reported that Nordic Nano has never manufactured any battery cells.

    The electrochemical evidence

    A key part of the Ziroth investigation is the exploration of electrochemical evidence, with voltage curves and cell expansion data showing the tested cell to be lithium-ion. Over 20 independent battery experts were consulted, including Julian Zanau from the Fraunhofer Research Institute, Dr. Yahim San from Justus-Liebig University, Tom Bicha from Leona, and Dr. Yuo Hesca from Seinäjoki University of Applied Sciences. 

    Electrek outlines the electrochemical evidence:

    “There are two key pieces of evidence. First, the voltage curves from VTT testing match high-nickel lithium-ion cells (NCM chemistry). The cell sits at 3.7-3.8 volts at 50% state of charge — right where lithium-ion cells operate. Sodium-ion cells don’t go significantly past 3.5 volts at 50% SOC.

    “The second piece of evidence is even more damning: VTT’s cell expansion data. When a battery charges, ions squeeze into the anode material, causing it to expand in a predictable pattern. A graphite anode produces a distinctive “kink” in the expansion curve around 50-70% state of charge, caused by how ions reorder themselves in graphite’s layered structure. The Donut Lab cell shows exactly that kink.

    “This is critical because sodium ions are physically too large to fit into graphite layers. The graphite anode signature proves the cell uses lithium ions.”

    The fundraising aspect

    Donut Lab raised $25 million from over 1,300 shareholders, most of which are small investors – over 900 hold 50 or fewer shares, and many were gathered through a crowdfunding exercise on Finland’s Springvest platform, performed in 2023 for Verge Motorcycles. When the restructuring of Verge Motorcycles took place and the Donut Lab became a spin-off, the company’s valuation transformed from that of a struggling motorcycle brand, to being the parent company of a highly valued portfolio, based on the “miracle” battery. An investor letter from Lehtimäki spoke of “a potential return on investment of up to 10x in just 12 to 18 months.”

    The Ziroth investigation argues that the process of presenting self-validated TDD in order to raise funds from inexpert investors was deliberately chosen, avoiding the more in-depth scrutiny that a venture capital investment firm would want to see.

  2. Semi-solid state battery development for the e-bike sector

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    Source: Electrek

    Advances in semi-solid state battery technology have been signalled by various players in the e-bike sector, with potential to significantly affect the longevity, safety and performance of e-bikes.

    The e-bike sector generally has seen growth and development over recent years, with incremental progress in motor technology, and software connectivity at the fore. Apart from gradual increases in capacity, battery technology – and the lithium-ion chemistry on which batteries are based – has, however largely stayed unchanged.

    Semi-solid state batteries would change that picture. In contrast to the chemistry of regular lithium-ion batteries, which contain a liquid electrolyte, semi-solid state batteries feature a gel-like substance which brings characteristics of enhanced thermal stability, improved safety, a substantially longer overall lifespan, and greater performance in extreme temperatures.

    These characteristics address many of the pain points e-bike riders experience with regard to lithium-ion batteries. Longer-lasting batteries that are quick to charge change ownership and usage expectations, while enhanced thermal safety is a clear plus point, and greater cold-weather performance expands usage scenarios.

    For the e-bike industry, semi-solid state batteries would present a shift of focus towards products’ lifespan and total cost of ownership, as well as the additional safety aspect. Integration of such battery technology may require manufacturing brands to adjust their supply chains, and potential higher up-front costs.

    The brands making an impact in the field of semi-solid state batteries for e-bikes are identified by Electrek as: T&D, which revealed products it had been developing at EICMA 2025; Giant is reported to have plans to begin integrating semi-solid state batteries into its e-bikes; and Ride1Up is launching a moped-style e-bike featuring a semi-solid state battery.

  3. Greenway Battery’s Indonesian facility achieves Certificate of Origin certification

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    Source: Greenway

    The Indonesian facility of LEVA-EU member Greenway Battery has received Certificate of Origin (COO) certification in December 2025, representing the establishment of a fully compliant production base for e-bike and LEV batteries outside of China. This certification allows them to serve global markets with reduced trade barriers and greater supply chain resilience.

    Greenway has charted the trajectory of the Indonesian factory, from Q4 in 2024 seeing its first locally-produced e-bike batteries exported to European customers, to now achieving the COO certification, unlocking the capability for compliant mass shipment, with immediate availability.

    Greenway’s strengths

    The company has highlighted its strategic advantages across three key markets:

    • European Union: non-China manufacturing addressing trade considerations; full EU regulatory compliance; optimized maritime shipping routes from Southeast Asia
    • North America: COO-compliant production positioned for preferential trade benefits; meeting supply chain diversification requirements; addressing non-China sourcing mandates
    • ASEAN Region: local production with AFTA trade benefits; reduced logistics costs and faster delivery; direct access to Southeast Asia’s rapidly growing e-mobility markets (Indonesia, Thailand, Vietnam, Philippines, Malaysia, Singapore)

    Benefits of COO certification

    • COO certification represents manufacturing capability at the Greenway Indonesia facility, with full production and quality control systems to meet the requirements of various relevant industry standards.
    • Localization development – Greenway’s products have met specified Regional Value Content (RVC) requirements, demonstrating integration with Indonesia’s industrial ecosystem.
    • A key breakthrough in market access – a compliant legal foundation for expansion into the North American market and accessing relevant preferential tariff benefits.
    • Reinforces supply chain resilience, with a stable and sustainable local supply chain which reduces dependency on single-source manufacturing.

  4. German research shows that sodium-ion batteries require different safety mechanisms

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    Source: Electrive, Journal of Power Sources Advances

    Image credit: Fraunhofer EMI

    Researchers in Germany have conducted tests comparing the behaviour of sodium-ion batteries to lithium-ion batteries under certain conditions, discovering that safety mechanism design is not a one-size-fits-all scenario.

    The research was jointly conducted by the Federal Institute for Materials Research and Testing (Bundesanstalt für Materialforschung und -prüfung, BAM), the European Synchrotron Radiation Facility (ESRF) and the Fraunhofer Institute for High-Speed Dynamics (EMI). The research was undertaken to investigate the viability of sodium-ion batteries as an alternative to more tried-and-tested lithium-ion systems, as there is potential for savings in resources and costs, and sodium-ion cell chemistry is considered to be relatively safe.

    The researchers noted that, to compete with lithium-ion batteries (LIBs), sodium-ion batteries (SIBs) need to be built with increased energy density. This in turn entails new requirements regarding battery safety, which need to be evaluated through rigorous battery abuse testing, aiming to deliberately initiate a thermal runaway event.

    The testing process

    Three types of batteries were tested, all cylindrical cells in the 18650 format.:

    • NFM cells (sodium-ion cells with nickel, iron and manganese)
    • LFP (lithium iron phosphate)
    • NMC532 (lithium nickel manganese cobalt oxide)

    BAM wanted to explore the behaviour of the SIBs in comparison to the more familiar LIBs types, and to examine if the built-in safety mechanisms are equally effective. Mechanical damage to the battery cells was simulated using a nail penetration test, where the cell is pierced to “trigger a critical damage event.” This normally leads to an internal short circuit, which, combined with the mechanical damage, can lead to thermal runaway.

    High-speed X-ray imaging technology developed by Fraunhofer EMI was used by ESRF researchers to visualise the internal results of this critical damage event.

    The results

    The tests on the familiar LIBs went as expected, with BAM stating: “The lithium iron phosphate (LFP) battery proved to be particularly stable. The lithium-ion battery with a nickel-manganese-cobalt (NMC532) cathode reacted in a controlled manner – its safety mechanisms worked as intended.”

    The researchers were surprised by the behaviour of the SIB, however, with the test leading to “an almost explosive reaction.”

    The use of the high-speed X-ray images enabled the researchers to determine that the cause of this behaviour was not due to the SIB’s cell chemistry, but instead the structure of the cell itself – specifically, a “failure of the cell’s venting system.”

    The cells’ venting systems are designed to ensure that excess pressure, in the event of an internal thermal reaction, is reduced by targeted venting. BAM noted that, “however, due to the rapid increase in pressure, the venting system was blocked by other components of the safety equipment, which led to the abrupt and violent reaction.”

    Nils Böttcher, head of the BAM battery testing centre, expanded: “Our investigations show that safety mechanisms cannot simply be transferred from one battery technology to another. Especially with new battery types such as sodium-ion cells, mechanical components such as venting systems must be specifically adapted and tested. Our findings do not call into question the fundamental safety of sodium-ion technology, but they do underscore the need to consider chemical composition and safety design together.”

    As a result, BAM is actively involved in the development of standards and norms in the field of sodium-ion battery safety.

    The research was published in issue 36 of the Journal of Power Sources Advances, where video recordings of the X-ray imaging of the tests can be viewed, revealing the internal behaviour of all three tested battery types.

  5. Cleantron deploys laser-welding to enhance lithium-ion battery production

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    Source: Cleantron

    LEVA-EU member Cleantron, a specialist producer of li-ion battery modules based in the Netherlands, has installed cutting-edge Trumpf laser-welding technology into its production line, allowing for increased output with enhanced product quality and reduced environmental impact.

    Cleantron’s product design features a fused welding technology, giving every welded cell its own fuse, and so offering intrinsic battery safety. Laser welding is the key to enabling this safety feature.

    Precision laser welding for multiple battery pack types

    The equipment is described by Cleantron as a key production enabler, performing laser welding with high accuracy, speed and reliability across a wide range of battery cells. From swappable lithium batteries for LEVs to li-ion battery packs for industrial equipment, the machine ensures consistent results.

    The system allows for rapid production changeovers and minimal downtime, enabling Cleantron to quickly shift between lithium ion battery 48v, 36V e-bike battery, and lithium ion battery 48v modules, and from low voltage to high voltage battery configurations.

    Durable welds and smart BMS integration

    Cleantron is able to ensure reliable connections within its lithium-ion battery products thanks to the Trumpf technology. The production line enables smart welding and built-in vision systems for high-quality joins, minimal defects, and full traceability.

    Combined with Cleantron’s proprietary battery management systems (BMS), the precision of laser welding directly supports safer, longer-lasting, and smarter battery solutions designed to perform in demanding environments.

    Efficient, environmentally friendly production

    Cleantron highlights that the Trumpf technology allows them to reduce waste and the need for reworking, and boost production capacity, enabling enhanced consistency of product quality at both small and large production quantities.

    With a wide range of lithium-ion battery products including those suited to the e-bike and light electric vehicle sectors, they provide reliable power solutions to European brands with minimal shipping miles, further boosting the sustainability of Europe-made products.

  6. Greenway unveils dual battery passport solutions for EU compliance

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    Source: Greenway

    At Eurobike 2025, the LEVA EU member recently presented two prototype Battery Passport solutions designed to meet the European Union’s upcoming Battery Regulation (EN 2023/1542) requirements, which will become mandatory in 2027. It has developed a streamlined digital passport for regulatory compliance and an IoT passport in partnership with OKGO.

    At Eurobike, the company premiered its dual-path approach, offering flexibility for light electric vehicle brands seeking either straightforward compliance or deeper system integration

    The first option – the Greenway Compliance Passport – is a streamlined, standalone digital passport designed to ensure core regulatory compliance. It targets manufacturers seeking a simple, reliable pathway to meet the 2027 milestones without additional system complexity.

    The second option – the IoT-Integrated Passport – has been developed in partnership with IoT service provider OKGO. This fully integrated solution embeds Greenway battery data into a broader connected platform, incorporating firmware management, analytics, aftersales support, and rider-focused services.

    Greenway says the two-tier offering allows customers to choose between rapid adoption for regulatory readiness or advanced integration for enhanced product intelligence and lifecycle management. Both approaches are designed to meet the EU’s transparency and traceability requirements for battery manufacturing, usage, and recycling.

    By introducing these solutions, Greenway looks set to position itself as an early mover in battery compliance innovation for the light electric mobility sector by offering future-ready options to manufacturers ahead of the EU’s regulatory deadline.