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Repair common Windows errors and clear accumulated junk for a smoother, more stable PC - no reinstall needed.Free scan · no reinstallA high-current charge during battery manufacturing—not a different charging habit for EV owners—boosted the average lifespan of tested lithium-ion cells by 50%, according to a 2024 study reported by SLAC National Accelerator Laboratory. The same factory formation step took 20 minutes instead of 10 hours under the conditions studied. The result is promising for cell production, but it does not show that existing electric vehicles or grid batteries will last 50% longer.
What changed—and when?
The researchers changed the initial charge, known as formation, which takes place near the end of lithium-ion cell manufacturing. They charged newly made cells at unusually high current during this first charge. Cells then undergo later manufacturing and, eventually, use; the intervention is not a setting available to drivers charging a battery already in a vehicle.
SLAC’s 2024 account of the study reports two results for the tested cells: their average lifespan increased by 50%, and the initial charge time fell from 10 hours to 20 minutes. These are study results, not consumer charging times, demonstrated vehicle-fleet outcomes, or a guarantee for cells made with other chemistries or production processes. The paper by Xiao Cui and colleagues appeared in Joule on 29 August 2024 (DOI: 10.1016/j.joule.2024.07.024); the collaborators included SLAC/Stanford, Toyota Research Institute, MIT, and the University of Washington. SLAC’s study report.
Why could a faster first charge make a cell last longer?
In ordinary battery operation, lithium ions move into the negative electrode during charging and return toward the positive electrode during discharge. The first charge also helps form a solid electrolyte interphase (SEI) layer on the negative electrode. Formation must establish this interface while preparing a cell for its later cycles.
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Using machine-learning analysis, the researchers identified formation current and temperature as influential conditions. Under the high-current conditions they studied, more lithium was deactivated up front. SLAC reports that about 30% was deactivated in the high-current process, compared with 9% under previous methods. The researchers’ explanation is that this early deactivation creates additional headspace, helping the cell cycle more efficiently later.
That is a counterintuitive trade-off: the tested cells lost more usable lithium at the outset, yet experienced lower subsequent losses and longer life. It does not mean lithium loss is generally desirable. The reported relationship applies to the studied cells and formation conditions; the evidence here does not establish that every cell chemistry, format, or factory line would get the same benefit.
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What the result means for EV and grid batteries
The finding matters because formation is a manufacturing step that can affect cell performance and production time before batteries are assembled into vehicles or grid-storage systems. Faster formation could potentially ease a production bottleneck, while longer-lived cells could be valuable over their service life. Those are manufacturing implications, not proof of a particular cost reduction or field-life improvement.
The reported work does not establish that commercial EVs or deployed grid batteries already last 50% longer, nor does it provide an independent real-world fleet or grid-storage result. The 50% figure refers to the average lifespan of batteries tested in the study, as reported by SLAC. It should not be applied as a prediction for a specific vehicle, storage installation, or battery already in use.
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Can owners use this charging method?
No. The change is made during factory formation, before a cell is incorporated into an EV or storage system. The study does not recommend that owners use unusually high charging currents on their vehicles, home batteries, or other devices. Follow the charging guidance supplied by the vehicle or battery manufacturer; this manufacturing result is not evidence that changing ordinary charging settings will extend an in-service battery’s life.
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