Natrion Launching First Active Battery Separator Made in US

Drop-in separator boosts energy density, diminishes costs

BINGHAMTON, N.Y., May 27, 2025 /PRNewswire/ -- U.S.-based battery technology company Natrion today announced it will begin accepting pre-orders for its first-generation flagship separator product in response to current global supply chain dynamics.  

The Gen-1 active separator, which uses Natrion's patented lithium solid ionic composite (LISIC) technology, is the first and only separator of its kind that mitigates common Li-ion battery cell degradation processes and is made in the United States. Importantly, the material delivers cell bill of materials cost efficiencies compared to legacy separator products and offers enhanced cell safety, including widened operating temperatures and benign failure modes, thereby mitigating fire risks.

The commercialization follows Natrion's establishment of production capabilities to manufacture the separator at scale, which were announced in fall 2024 and have since been ramped to gigascale volumes.

Natrion's Gen-1 Active Separator: A Breakthrough Solution

"Our mandate was to develop a superior battery separator that would not only reduce the bill of materials cost of making Li-ion batteries but also enhance their performance and safety, all while dropping into current gigafactory cell lines with zero disruption," said Natrion CEO and founder Alex Kosyakov. "We're proud to say we've accomplished that with our Gen-1 active separator, and we've done so as an entirely domestic product."

Innovation in Cell Function

Natrion's industry-leading separator technology leverages the company's patented Lithium Solid Ionic Composite (LISIC) technology. Whereas separators have always been inactive cell components, Natrion's LISIC-based variant possesses intrinsic liquid-independent ion transport properties. Rather than simply keeping cells' anodes and cathodes apart and hosting liquid electrolyte as standard inactive separators do, the Gen-1 active separator operates without liquid to mediate selective charge transport between anode and cathode and block parasitic chemical processes and degradation mechanisms.

"This is a breakthrough for separator technology. In the past, only the cathode and anode could be manipulated to substantially influence cell performance," said Natrion Chief Technology Officer Duke Shih. "Usually only a diminished part of lithium batteries' full theoretical power capacity can be accessed at any given time. Our active separator makes more of a cell's capacity accessible, offering a new method of augmenting performance capability with a simple drop-in component."

Superior Energy Density & Performance

Natrion's Gen-1 active separator not only improves existing Li-ion battery cells, but also enables next-generation chemistries like Li-metal and Li-sulfur to be viable at scale by overcoming engineering obstacles like dendrite propagation and metallic lithium instability. Recent internal control testing of Natrion's separator in multi-layer Li-metal pouch cells have yielded 450 Wh/kg energy density performance, a 50% improvement over current Li-ion cells, and 15-minute charging capability.

In Li-ion, the control testing also showed effective energy density increases of 10%-15% with Natrion's Gen-1 active separator. These increases in energy density are accomplished through boosted discharge capacity availability and diminished liquid electrolyte volume.

Low-Cost, Drop-in Technology

The combined impact of reduced electrolyte and increased energy output equates to a lower cost to manufacture Li-ion cells on a $/kWh basis — a critical metric in the battery industry today and a major advantage for the gigascale domestic production required by market demands.

In addition, Natrion's Gen-1 material is mechanically identical to legacy separators with equivalent or better thinness, flexibility, and tensile strength. This design has enabled it to be a universal, drop-in component compatible with all cell types, form factors, and assembly processes such as jelly roll and Z-folding, eliminating manufacturing barriers.

Made in America, Bolstering Domestic Supply

Natrion accelerated the launch of its all-American Gen-1 product in response to the intensifying lack of domestically-sourceable separator in the US. Sources estimate that onshore local demand will outpace supply by over 5 billion square meters per year as early as 2030 (McKinsey, 2024).

As a longstanding partner to the U.S. Department of Defense, Natrion has secured capabilities to produce the Gen-1 material entirely in the U.S. with only domestic materials. The company's production line is in Upstate New York and its supply chain is fully insulated from tariff interruptions, making it ideal for manufacturers seeking IRA-compliant American-made components.

Natrion is now accepting conditional pre-orders for its Gen-1 active separator, subject to availability. More information as well as material specifications are now accessible on the company's website. For more information, please contact [email protected] or visit www.natrion.com.

About Natrion
Natrion is a leading battery material pioneer developing the components needed to secure our future. Started in 2018, the company's flagship active separator has received industry awards for its innovative design. A recipient of numerous Department of Defense contracts, Natrion is also partnered with leading research and academic institutions; cutting-edge organizations including LG Energy Solution; and investors including Mark Cuban, TechNexus Venture Collaborative, and Tamarack Global. The company is headquartered in Binghamton, New York with operations in Champaign, Illinois.

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SOURCE Natrion