The Science Behind Neocarbonix®

Overcoming the fundamental limitations of today's batteries by replacing conventional binders and additives with a composite binding mesh.

The Flaw in Conventional Electrodes vs. Neocarbonix®

Conventional Li-ion batteries rely on legacy binders. These binders are insulators, creating bottlenecks for electron transport, increasing resistance, and limiting both power and energy density.

Conventional Electrode

  • Blocks electron flow between active material particles.
  • Requires NMP solvent for processing and recovery.
  • Contains PFAS ("forever chemicals") facing global regulatory phase-outs.
Conventional Render
Render
Conventional SEM Scan
SEM Image

Active Material

e.g., NCM, LFP, GRAPHITE, SI-C

Responsible for storage and release of energy.

Binding Agent

e.g., PVDF

Glues the materials together and to the foil.

Conductive Additive

e.g., CARBON BLACK

Added specifically to improve electrical conductivity within the electrode.

Neocarbonix® Electrode

  • Replaces conventional binders and additives with a highly conductive, composite binding mesh.
  • Enables solvent flexibility, reducing drying energy costs and capital expenditure.
  • 100% PFAS-free, ensuring long-term sustainability.
NXSP Render
Render
NXSP SEM Scan
SEM Image

Active Material

e.g., NCM, LFP, GRAPHITE, SI-C

Higher active material mass loading and energy density achieved with NXSP.

NXSP

COMPOSITE BINDING MESH

  • • Replaces both conventional binders and conductive additives with a composite binding mesh.
  • • Enhances electrical conductivity by >10x compared to conventional electrodes.
  • • Creates a thermally conductive network with superior heat transfer.

The Neocarbonix Advantage

An unparalleled suite of cost, performance, and sustainability benefits.

Cost

Generates significant cell cost savings by enabling thicker electrodes with less inactive material and lower capex.

Energy

Drastically improves volumetric and gravimetric energy density by enabling a thicker active material layer and higher conductivity.

Fast Charge & Power

Enables fast charging and high-power capabilities without sacrificing energy density.

Cycle Life

Extends useful cycle life by providing superior mechanical flexibility and adhesion over reference electrodes.

Sustainability

A PFAS-free structure that simplifies end-of-life recyclability and significantly reduces manufacturing energy consumption.

Chemistry Agnostic

Seamlessly integrates with any cathode (NCM, NCA, NCMA, LFP, and more) or anode material, including high-capacity silicon.

Standard Manufacturing Process

Adopting Neocarbonix does not require billions in capital expenditure. It is a true drop-in solution designed specifically for existing roll-to-roll gigafactory infrastructure.

NXSP Precursor

NXSP

A drop-in solution replacing conventional binders and additives with a carbon binding structure. Mimics conventional rheology.

Standard Mfg Process
Slurry Mixing

Slurry Mixing

Add NXSP directly to conventional mixers alongside active materials.

Electrode Coating

Electrode Mfg.

Coating Drying Calendering Slitting Final Drying
Cell Assembly

Cell Assembly

Cutting Stacking Contacting Enclosing
Real-World Application

Sustained Power for Drones

When applied to advanced NCA cathodes, Neocarbonix fundamentally shifts the performance envelope for applications requiring sustained high power, outperforming conventional baselines across every key metric.

The Electrode Advantage

By replacing conventional binders and additives, NXSP achieves a remarkably high 99% Active Material (CAM) content compared to the 96% industry standard. The 3D carbon matrix also provides excellent mechanical flexibility and demonstrates 4x superior adhesion over reference electrodes, even at high mass loadings.

The Cell Level Impact

Higher CAM content and higher mass loading translate directly to higher energy density. More importantly, the continuous carbon network drastically lowers internal electrode resistance.

The Result: >70% More Usable Energy at 5C

In high-discharge scenarios critical for sustained flight, NXSP designs maintain capacity far better than conventional cells, delivering significantly more usable energy precisely when you need it most.

Performance Radar Chart
Superior Across All Metrics

Testing shows NXSP systematically outperforms conventional baselines in Specific Energy, Specific Power, Cycle Life, Adhesion, and overall Cost-effectiveness.

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