Over his 15 year tenure at the company, Dr DasGupta has managed every aspect of the company’s business and spearheaded the development and manufacturing of new sustainable battery technologies. Dr DasGupta has impressive scientific and business credentials, having attended the Imperial College of London, Massachusetts Institute of Technology, and the University of Cambridge, where he received his Doctorate in Materials Science.
Electrovaya has extensive IP and develops and manufactures proprietary LIBs and battery systems for energy storage and heavy-duty electric vehicles based on its Infinity Battery Technology platform (IBT), which delivers LIB safety and life expectancy that rank among the highest in the industry. Notably, a relatively small team of about 40 engineers and seven PhDs are credited with developing this remarkable technology.
Headquartered in Ontario, Canada, Electrovaya has two operating sites in Canada and a 52-acre site with a 135,000ft2 manufacturing facility in Jamestown, NY, USA, where it plans to deploy a LIB gigafactory.
Diving into battery separators
According to Dr DasGupta, the essence of the Infinity technology is its proven capability to provide the safest and longest cycling NMC-based LIBs on the market.
One of the key contributors to the safety performance of the Infinity LIB is its unique ceramic composite cell separator, which provides:
- Effective fire propagation prevention technology
- Reliable ceramic separator for higher levels of thermal protection to reduce the likelihood of unsafe events
- UL2580 safety standard compliance
A typical LIB cell comprises positive and negative electrodes, a liquid electrolyte and a separator. The latter is a porous dielectric membrane sandwiched between a cell’s positive and negative electrodes to prevent their electrical contact while permitting the ion transport required for electrochemical reactions.
The performance and safety of LIBs depend upon the separator’s porosity, wettability, mechanical strength and thermal stability. According to the Federal Aviation Administration, numerous battery-related accidents have occurred due to the failure of cell separators. If the separator fails to prevent electrical contact between the electrodes, the ensuing short circuit may ignite the highly volatile and flammable vapour of the organic electrolyte and cause a fire, which is extremely difficult to extinguish due to oxygen fed to the fire by NMC-based cathodes. Lithium dendrites can also cause internal shorting due to mechanical penetration of the separator.
Separators are classified into microporous polyolefin, nonwoven, and ceramic composite separators. Polyolefin separators are widely used in commercial LIBs, despite their low electrolyte affinity and melting temperature of 130°C.
Substantial research on LIB separators has led to various designs, such as functionalised polyolefin, polyolefin/nonwoven multilayer, nonwoven, and ceramic composite separators with improved electrolyte uptake and thermal stability.
Not all ceramic separators are made equal
Ceramic composite separators (CCS)have undergone rapid development due to their enhanced safety. In contrast to polyolefin separators, they hardly shrink when heated and are more hydrophilic due to their inorganic powder component.
The first samples developed by Prosini et al. comprised a PVdF-HFP polymer combined with metal oxide powders of MgO, LiAlO2 or Al2O3 . However, despite excellent thermal stability and wettability, their mechanical properties were unsuitable for winding.
In 2015, Litarion, a German subsidiary of Electrovaya, made a decisive improvement in mechanical stability by introducing a new, flexible ceramic separator, SEPARION. These separators were made from ceramics and a porous polyethylene terephthalate (PET) non-woven homogenous single- layer substrate.
CCS was composed of the ceramic coating suspension embedded into the substrate. In addition to improved mechanical stability, SEPARION withstood unusually high temperature incursions, making the LIBs much safer. Electrovaya validated the technology in more than two million large-format LIB cells used in EVs and grid-scale energy storage. Called a ‘full ceramic separator’, SEPARION consistently performed better than coated polyolefin-based separators, demonstrating dramatically increased LIB cycle life, thus substantially reducing its cost per cycle.
“The flexible ceramic separator, SEPARION, is a proven technology providing excellent safety and performance for advanced battery applications,” said Dr Kai-Christian Möller, Fraunhofer Battery Alliance, Germany, at the time.
Following the successful adoption of SEPARION technology in 2015, Electrovaya launched the Infinity cells. Other companies, including Freudenberg Performance Materials, ENTEK Membranes, Asahi Kasei and Porous Power Technologies, are producing ceramic-coated separators in contrast to Electrovaya’s embedded CCS.
Electrovaya’s patented ceramic separator technology
Electrovaya owns 30 key ceramic separator patents and continues to file new ones. Some patents are concerned with designing, manufacturing and applying CCS in LIBs and a novel battery architecture. One of the patents granted in 2013 is titled ‘Separator comprising an organic- inorganic adhesion promoter’.
The invention provides a process for producing a separator comprising the steps of:
- Providing a sheet-like porous substrate
- Providing a solvent
- Providing ceramic particles
- Providing an adhesion promoter
- Preparing a slip by mixing the solvent, the adhesion promoter and the ceramic particles
- Coating the substrate with the slip
- Thermally drying the coated substrate to obtain the separator
- Wherein the solvent used is a mixture of water and at least one organic component
- Wherein the adhesion promoter used is a mixture of silanes and at least one thermally cross-linkable acrylic polymer
- Wherein the slip is admixed with a carboxylic acid preparation having a melting point below 80°C
- Wherein the slip is admixed with a defoamer component free from silicone oil
The separator obtained in this way improves mechanical properties due to the acrylic polymer in the adhesion promoter, whilst the silane content of the adhesion promoter significantly increases the ceramic content and hence the thermal stability. Tests show that industrial production of the organic/inorganic adhesion promoter mixture would be impossible without admixing the carboxylic acid composition and the silicone oil-free defoamer component.
Only these two processing auxiliaries make the first production of organically and inorganically bound separators possible. The ceramic particles selected from Al, Zr, Si and Ti metal oxides have a nonspherical structure. The acrylic polymer, such as Plextol BV 595, is introduced into the production process as a dispersion. A separator of this type is from 20 to 23μm thick and has up to 80% ceramic content, while maintaining 60% porosity.
As a precursor to the SEPARION technology, the patent gives the reader a basic understanding of its complexity and scientific achievements. Over the years, Electrovaya’s scientists and engineers have dramatically improved the patent’s fundamentals and adopted a comprehensive, industrially viable manufacturing process.
Electrovaya’s CCS prevents LIB cell failure at high temperatures and outperforms some premium polyolefin ceramic-coated separators (Fig 1).
The mainstay Infinity-based cell EV-52
Electrovaya’s efforts have resulted in Infinity, a battery product with an admirably long cycle life. Electrovaya’s mainstay cell, the EV-52 (Fig 2), is UL2580 certified and meets the most stringent customer requirements.
The cell features a gravimetric energy density of 220Wh/kg. Tesla’s LIB is capable of 240Wh/kg, but its life expectancy and safety are not in the same league as Infinity (Fig 3).
The EV-52 Cell, with a nominal capacity of 54Ah, comprises NMC cathode and graphite anode. Electrovaya’s patented ceramic separator and other technologies enhance its performance and cycle life. By 2018, the company developed a cell with market-leading cycle life featuring a host of technologies that reduced parasitic reactions, which commonly lead to reduced cell capacity as cycling progresses.
The Infinity cells also presented very high levels of general performance. The nominal voltage range is 3.7V. It can be relatively quickly recharged at a continuous 2C rate or a higher 4C rate for 15 minutes. The constant discharge rate is 3C with a peak of 5C for 10 minutes. The cell endures up to a 10C rate for five seconds without exceptional cooling, demonstrating a class-leading low internal resistance. The cell operating temperature range is -30°C to 55°C.
The cell features an industry-leading cycle life of 9,000 cycles at 100% SOC and 1C/1C rate. Its dimensions LxWxT are 249 x 155 x 12 mm and it weighs 920g.
Electrovaya continues its diligent work to improve the Infinity technology platform. “We are making great strides in improving it,” said Dr DasGupta. “Significant input has been obtained from ceramic-based separator technologies, which we have developed.”
In addition to the separator, Electrovaya has developed high-quality electrodes and high temperature optimised electrolytes, contributing to extraordinary cycle life and cell performance. It also created a highly efficient UL991-compliant battery management system (BMS). Built in-house, the BMS is not dependent on outside suppliers and has assured reliability. The company also introduced the Six-Sigma assembly processes typically favoured by the automotive OEMs for harmonious production and superb quality.
Low-voltage batteries for forklifts
Electrovaya launched the Infinity-based low-voltage forklift 24V and 36V product lines in 2018.
Electrovaya cut its teeth supplying batteries for forklifts, mining vehicles, and battery energy storage systems (BESS), where its technology was mission-critical, failure was not an option, and safety was in high demand.
One of the world’s leading producers of EVs, the Chinese company BYD, also makes forklifts with batteries based on its Blade technology. These LFP batteries are claimed to be the industry’s safest, longest-lasting and most versatile LIBs featuring the following characteristics:
- Environmentally friendly: No heavy metals or toxic chemicals
- Long life: After 10,000 cycles, the battery retains 65% of its original capacity, and is covered with a 10-year warranty – the longest in the industry
- Safe: Reliable operation from -40° C to 60° C BYD uses LFP cathodes, which typically are conducive to a gravimetric energy density about 30% lower on the cell level than the NMC cathodes used by Electrovaya’s Infinity batteries.
BYD claims its second-generation Blade batteries can achieve 220Wh/kg – on par with the Infinity batteries. Although important for cars, these metrics are less significant for forklifts, for which volumetric energy density is much more critical. In this regard, NMC cathodes are still ahead of their LFP counterparts.
Regarding safety and endurance, Electrovaya’s forklift- type LIBs are in the same ballpark as BYD’s – a tremendous achievement for a much smaller company than the Chinese Goliath.
“Our separator is over 90% by weight ceramic. This enables much higher thermal stability and much better safety for our battery products,” said Dr DasGupta. As previously mentioned, the remarkable properties of the Infinity separator contribute to the competitive capabilities of the Electrovaya battery-based forklifts. The successful application of batteries in forklifts and other material handling equipment opens the doors for Electrovaya’s launch of battery systems for airport ground support equipment (GSE) to reduce emissions and noise pollution on the tarmac.
Electrovaya’s Infinity technology is well-suited for GSE applications requiring exceptional safety, durability and performance in extreme temperatures. Airport equipment operates continuously in harsh conditions with minimal downtime tolerance, making these attributes particularly valuable. The emphasis on long cycle life is especially relevant for GSE, where equipment typically remains in service for 7-10 years, allowing Electrovaya to be more viable than the competitors with less durable solutions (Tables 1 and 2).
Infinity high-voltage battery system
Electrovaya launched the Infinity-HV system in 2023 by supplying it for off-road military vehicles. Commenting on this important milestone, Dr DasGupta said, “We are excited that our first Infinity-HV battery product met the extreme performance requirements for this off-road autonomous defence application, which represents some of the most difficult validation testing available. These follow-on orders are a testament to the exceptional performance of the Infinity-HV technology for mission-critical applications in general.”
The Infinity-HV systems target mission-critical and heavy-duty high-voltage applications, including EVs, defence and other energy storage applications requiring unquestionable performance and safety. Production of the Infinity-HV is planned at the Jamestown facility.
Electrovaya’s markets
The first proof of Electrovaya battery viability was its first big order in 2018 from the Canadian Walmart distribution centre for a retrofit of 156 lead-acid battery forklifts. Electrovaya says that after seven years of unfaltering operation the batteries still had 90% of energy retention. They’re now in their second life and running strong, where previously used lead-acid batteries required replacement after three years of operation.
Forklifts and other material handling vehicles grow around 20% annually, and will continue for the next five years. Toyota Material Handling and Raymond forklifts may provide a sizable USA market for Electrovaya in light of Toyota’s announced Columbus, USA facility expansion. In 2019 and 2020, the Raymond Corporation (a 100% subsidiary of Toyota and North America’s largest electric forklift manufacturer) announced strategic agreements to use Electrovaya batteries as part of its electric forklift and battery product line.
Electrovaya is a sustained battery supplier to global defence contractors for unmanned ground vehicles and cooperates with top five Australian mining companies to electrify their dump trucks. The company has also signed a $1.3m development agreement with Janus Electric in Australia for swappable battery systems. The previously mentioned airport GSE is a considerable part of Electrovaya’s marketing strategy.
In summary, Electrovaya underscores, “We will not match the leading global battery OEMs on cost unless we get to their scale”. However, its ceramic separator gives the company a viable line of defence compared to any LIB that uses polymer separators, which shrink at 100-120°C and may cause thermal runaway.
The developed and perfected in-house BMS gives the Infinity technology a second line of defence, enabling safe use of NMC chemistry.
In this regard, Electrovaya’s technology is arguably the only one that provides a viable safety alternative to solid electrolytes (still experimental) and LFP, which has lower volumetric energy density.
Solid-state battery development
Electrovaya Labs is working on solid-state batteries, which promise a significant increase in energy density and a higher flammability threshold. The company’s expertise with ceramic-based separators is an asset in solid electrolyte development, as ceramics play a crucial role in such technologies. The challenges are high ionic resistance interfaces between solid electrolytes and cathodes, and the necessity to apply external pressures.
Electrovaya believes a joint venture would likely be the best way to commercialise its solid- state technology. Solid-state technology will serve niche applications such as drones, aviation and luxury EVs, where energy density is critical and longevity is less of a concern. “Solid-state would complement, not replace, our core business”, said Dr DasGupta.
Looking confidently into the future
Electrovaya IP comprises over 100 patents (developed and acquired) covering ceramic separator technology, battery manufacturing processes, and pioneering battery designs. These patent awards include innovations in electrode microstructure and environmentally friendly electrode manufacturing.
As previously mentioned, Electrovaya owns a proven proprietary ceramic separator technology, enabling it to confidently compete with other advanced LIB technologies globally.
“This technology has saved the company,” said Dr DasGupta. “Before, Electrovaya was essentially on life support.” The CEO alluded to the fact that, owing to his and his team’s efforts, Electrovaya has experienced a dramatic financial improvement, moving from a company struggling for survival to a sure-footed battery OEM. The company’s revenue has ramped from modest to an encouraging $60m in fiscal 2025. Profitability is also commendable, as it reported eight consecutive quarters of positive adjusted EBITDA, profitable since 2023.
Electrovaya is cautiously optimistic, saying, “With all the uncertainties on material prices as of late, it is harder to predict things, but we expect that the Jamestown cell and module production are going to enhance margins, whether the IRA exists or not at that point.
“We are at a $140m market cap today. Our Mississauga facility has about $100m in annualised capacity. We are currently running two shifts, and we are roughly at 60% capacity. Last year, we did $45m in revenue. We aim at $60m this year, and there’s still room to grow. We want to see a $1bn market cap in five years. We have a clear roadmap: grow into new verticals, get Jamestown to full capacity, and build the foundation for a gigafactory.”
On 19 March 2025, the Canadian Globe and Mail reported that after the Canadian government rejected Electrovaya’s 2021 funding request for a lithium-ion battery plant in Ontario, the company instead secured a site in southwestern New York and received US$50.8m in loans and additional state subsidies.
The plant, set to begin operations in 2025, will create 250 US jobs while maintaining a smaller facility in Mississauga with 100 employees to serve overseas markets.
Electrovaya was surprised when Canada later committed billions to attract foreign EV battery plants. Why was Canada funding them but not a domestic innovator in the same field? Dr DasGupta said in December, “I look at that as a bit of folly, especially since Canadian companies have received little of those incentives to set up and scale manufacturing here. We were feeling unloved.”
The Canadian government may have inadvertently benefited Electrovaya. Due to a trade war, products from its New York factory, aimed at the American market, will not face the same tariffs as Canadian products.
