NOVONIX Secures US and Europe Patents for All-Dry, Zero-Waste Cathode Synthesis Technology

NOVONIX has been granted its foundational patent in the United States and Europe for our all-dry, zero-waste cathode synthesis process. This patented technology is the first of its kind in the United States (US12378132) and Europe (EP4021854), eliminating the need for precursor materials and directly converting raw metal feeds into finished NMC cathode active materials.

This milestone builds on the Japanese patent (JP7504195B2) granted in 2024 and affirms NOVONIX’s commitment to advancing the future of energy storage through the development of high-performance, sustainable, and cost-efficient materials.

Transforming Cathode Production

The production of the cathode material is a critical component of lithium-ion batteries, driving performance, cost, and sustainability of the battery cell. Traditional cathode production methods rely heavily on liquid-based processing and generate significant waste byproducts, adding both expense and environmental impact.

NOVONIX’s patented cathode synthesis process introduces a transformative all-dry, zero-waste approach that delivers:

• High-quality single-crystal NMC powders
• Elimination of liquid processing steps
• Significant reductions in waste generation
• Lower energy consumption and costs

This breakthrough both enhances battery material performance and sets a new benchmark for sustainability in battery manufacturing.

A comparison of the current precursor synthesis process vs. NOVONIX's precursor-free cathode synthesis technology.

Discover All-Dry, Zero-Waste Cathode Synthesis

NOVONIX’s patented cathode process is a world-first, fully scalable method for producing NMC cathodes without the traditional precursor step. Download the whitepaper for an evaluation of the technology on NMC622 at the pilot scale.

Download the Whitepaper

Backed by Independent Study

In September 2023, NOVONIX released the results of an engineering study conducted by Hatch Ltd., a global engineering consultancy firm, validating the benefits of our process. The study highlighted:

• ~27% reduction in power consumption
• Practically zero waste byproduct generation
• ~50% lower processing costs (excluding feedstock)
• ~30% lower capital costs

These improvements demonstrate the potential of NOVONIX’s cathode process to reshape the economic and environmental footprints of cathode production at commercial scale.

Scaling for the Future

NOVONIX has commissioned a 10 tonnes per annum pilot-scale facility housed in a 35,000 sq. ft. production space to showcase the scalability and flexibility of this patented process. This facility enables the production and sampling of mid- and high-nickel single-crystal NMC cathode materials, such as:

• NMC631
• NMC811
• NMC9055

These materials have been successfully validated in full-cell testing and sampled to partners worldwide, performing on par with leading cathode materials already in the market.

NOVONIX's pilot-scale facility in Nova Scotia, Canada.

A Platform for Cathode Innovation

While initial demonstrations focus on well-known NMC compositions, our technology extends across a continuum of chemical formulations, providing flexibility to meet the needs of diverse applications. With multiple patents filed worldwide, NOVONIX is building a robust intellectual property portfolio to support the global battery industry.

Interested in a deeper dive? Watch our on-demand webinar.

All-dry, zero-waste cathode synthesis: Technology-enabling solutions to sustainable, low-cost materials production

Featuring Dr. Mark McArthur, Director of Cathode Technology at NOVONIX, this session explores how our patented method delivers high-performance cathode materials while advancing the battery industry toward a more sustainable future.

Watch the Webinar

Looking Ahead

These patents reinforce NOVONIX’s focus on driving sustainable innovation in energy storage. By combining breakthrough science with scalable pilot production and an expanding patent portfolio, we are accelerating the development of cleaner, more cost-effective batteries that power the future of transportation and grid-scale energy.