Sion Power is expanding its Licerion® lithium-metal battery program to supply cells and battery systems for US defense and aerospace. The cells are engineered to exceed 500 Wh/kg, up to 200 Wh/kg more than current advanced lithium-ion technology, even with silicon anode enhancements.

The platform covers both primary (single-discharge) and secondary (rechargeable) configurations. Target applications include long-endurance UAS, tactical and counter-UAS drones, missile and loitering munition platforms, autonomous maritime and ground vehicles and space systems. Sion Power operates a 110,000 sq ft cell manufacturing facility in Tucson, Arizona, and says it can demonstrate cells and integrated battery systems today, and expects initial product shipments in late 2026.

Lithium-metal anodes store substantially more energy per kilogram than graphite because lithium metal is lighter and more electrochemically active. For weight-constrained platforms, closing the gap from 300-350 Wh/kg for advanced Li-ion to 500+ Wh/kg translates directly into longer endurance and expanded payload capacity. Sion Power’s expansion also responds to US policy momentum—NDAA provisions support domestic battery supply chains and highlight demand for American-manufactured advanced cells.

“Our lithium-metal technology provides the step-change in energy density required to support longer-range missions, increased flight duration and higher payload capability while maintaining a U.S.-based manufacturing capability aligned with national security priorities,” said Pamela Fletcher, CEO of Sion Power.

“By combining high-energy lithium-metal chemistry with advanced battery pack engineering, Sion Power enables defense integrators to unlock two to three times increases in mission endurance, significantly extended operational range and dramatically higher payload capacity compared with conventional lithium-ion and lithium-polymer batteries used in today’s unmanned systems,” said Tracy Kelley, chief science officer at Sion Power.

Source: Sion Power

Vishay Intertechnology has launched the VODA1275, an automotive-grade photovoltaic MOSFET driver that delivers 8 mm creepage distance and CTI 600 mold compound in a compact SMD-4 package. The device targets high voltage automotive applications including pre-charge circuits, wall chargers, and battery management systems for EVs and HEVs.

The VODA1275 delivers 20 V open circuit voltage, 20 μA short circuit current, and 80 μs turn-on time—three times faster than competing devices, according to Vishay. The driver provides reinforced isolation with a working isolation voltage of 1260 Vpeak and isolation test voltage of 5300 VRMS, making it suitable for 800 V+ battery systems. The device is AEC-Q102 qualified and meets automotive reliability standards.

The high open circuit voltage allows designers to use a single MOSFET driver instead of two drivers in series, which was previously required for higher voltage applications. This simplifies circuit design and reduces component count in systems that need to drive MOSFETs and IGBTs reliably at high voltages. The driver can also enable custom solid-state relays to replace electromechanical relays in next-generation vehicles.

The optically isolated device draws power from an infrared emitter on the low voltage side, eliminating the need for an external power supply on the isolated side. “The VODA1275 features the industry’s fastest turn-on times and the highest open circuit voltage and short circuit current in its class,” the company stated. The driver is RoHS-compliant and halogen-free. Samples and production quantities are available now with eight-week lead times, priced at $1.20 per piece for US delivery.

Source: Vishay Intertechnology

Magna, one of the world’s largest automotive suppliers, has introduced DHD REX, a single-motor dedicated hybrid drive for range extended electric vehicles (REEVs). The ready-to-integrate system is built on a modular architecture designed for OEMs operating across markets with different regulatory requirements, infrastructure conditions and customer expectations.

DHD REX runs in three modes: pure electric driving, a generating mode in which the ICE charges the battery for range extension, and an optional parallel hybrid mode for highway performance. The single-motor design reduces cost and packaging complexity compared to dual-motor configurations. Magna says the system is validated across B through E vehicle segments in AWD layouts including SUVs, and integrates into both ICE-based platforms and BEV-derived architectures.

In a range extended EV, the combustion engine runs as a generator in most conditions rather than driving the wheels—the electric motor handles propulsion. DHD REX’s optional parallel mode adds the ability for the ICE to contribute mechanical drive at highway speeds, where the efficiency penalty of the generator-motor conversion path is most pronounced.

DHD REX complements Magna’s DHD Duo, a dual e-motor dedicated hybrid already in series production. The single-motor architecture targets OEMs that want range extension capability without the cost and packaging of a two-motor system, and the modular design adapts to both ICE-based platforms being electrified and native BEV architectures adding a range extender.

“DHD REX reflects our commitment to adaptable, customer-focused solutions that support a wide range of performance and market expectations,” said Diba Ilunga, President Magna Powertrain.

Source: Magna

Off-the-shelf controllers with safety certifications are giving e-mobility engineers a false sense of security.

An off-the-shelf BMS with a third-party functional safety certification sounds like a solved problem. SIL-rated, ASIL-rated, ready to drop into your e-mobility battery pack. But according to Rich Byczek, Global Chief Engineer for Batteries at Intertek, that certification probably doesn’t cover what you think it covers.

“Certified BMS systems, meaning certified systems that have functional safety certifications from a third party, don’t necessarily address these functions,” Byczek told Charged during a recent webinar (now available to watch on demand). “They just look at the controller as a more generic electrical system.”

The problem: most certifications evaluate the controller hardware against a general integrity standard (IEC 61508, ISO 26262 or ISO 13849). They verify that the electronics are reliable. They don’t verify that the controller monitors individual cell voltages, manages cell-level temperature limits or handles the specific failure modes of lithium-ion chemistry.

Fuses don’t protect at the cell level

The gap is sharpest with passive protection. A pack-level fuse can interrupt a gross overcurrent event, but it’s blind to an individual cell in a series string being driven past its voltage limits. That requires active, per-cell monitoring, and a generic certified controller may not have the inputs and outputs to deliver it.

For e-mobility systems specifically, Byczek stressed that the failure modes and effects analysis (FMEA) must evaluate overvoltage, undervoltage, overcharge, overdischarge, over- and under-temperature, short circuit and excessive current, all at the cell level. “We look at those at the cell level, not only at the macro or battery pack level,” he said.

This is a different world from portable devices, where legacy standards like IEC 62133 rely on type tests and single-fault evaluations. Those standards were designed for products a user could set down and walk away from.

E-mobility doesn’t work that way. “You’re literally riding on top of that battery, potentially going at a fairly high speed,” said Byczek. “You can’t just get away from it.”

Start with the FMEA, not the certificate

The fix isn’t complicated, but it does require work. Start with an FMEA that covers every safety-critical function your BMS must perform, at the cell level. Then verify that your controller (certified or not) actually has the architecture to deliver each one. A certified controller is a starting point, not a finish line.

The standards themselves can be mixed and matched. SIL, ASIL and Performance Levels don’t map one-to-one, but regulators accept cross-framework approaches as long as your risk assessment demonstrably covers every identified hazard. For BMS systems, you’re typically targeting SIL 2, ASIL B or PLc, but the specific level matters less than proving your system can fail safely when a sensor drifts, a resistor opens or a communication link drops.

For teams pivoting from automotive EV programs into adjacent markets like forklifts, floor scrubbers and personal mobility devices, this is the adjustment that matters most. The batteries may be smaller, but the safety obligations are not.

Watch the full webinar: Rich Byczek’s complete presentation on applying functional safety to e-mobility battery systems is available on demand.

ENNOVI has secured a German patent for its adhesive-free lamination technology for battery cell contacting systems (CCS). The laser-based process eliminates the adhesives used in conventional hot and cold lamination, and the company says the technology is already validated—meaning OEMs can adopt it without having to prove out the manufacturing process themselves.

CCS components connect and integrate individual cells within a battery module, typically combining busbars, voltage sense lines and the physical laminate layers that hold them together. Conventional CCS lamination bonds those layers using adhesives in hot or cold press processes. ENNOVI’s laser lamination achieves the same bond without adhesive material. The technology supports cylindrical, prismatic and soft pouch cell architectures. With this patent, ENNOVI now offers three lamination options (hot, cold and adhesive-free) for its CCS designs, giving battery engineers a process choice matched to their cell format.

The patent’s main commercial argument is risk reduction. Developing a new lamination process in-house takes time and carries qualification uncertainty; using a pre-validated, patented technology lets engineering teams skip that work. ENNOVI supports co-development and tailored engineering engagement, which it says allows OEM partners to maintain control over their product roadmaps.

The technology was developed at ENNOVI’s Advanced Solutions Engineering Center in Neckarsulm, which includes prototyping, testing and R&D capabilities. The facility holds ISO 9001:2015 and TISAX certifications—the latter covering automotive supply chain data security requirements.

“Automotive OEMs and battery manufacturers can design in the unique features of adhesive-free lamination, reduce engineering risk by using a technology that is already validated, rather than reinventing it,” said Randy Tan, Product Portfolio Director for Energy Systems at ENNOVI.

Source: ENNOVI

Fraunhofer IFAM has developed a dynamic impedance spectroscopy method for real-time battery diagnostics, allowing continuous monitoring during operation. This innovative approach enhances performance, safety, and lifespan by enabling precise, instant detection of internal issues and optimising charging processes. Its applications extend across electric vehicles, renewable energy, and critical power systems.

The post Real-Time Battery Impedance Monitoring: A Breakthrough in Safety, Performance, and Lifespan appeared first on SolarQuarter.

ZincFive^® has closed out 2025 with major industry recognition, earning top honors in the 2025 Power Technology Excellence Awards across four categories: Innovation, Product Launch, Safety, and Environmental Excellence. Powered by GlobalData’s business intelligence, the awards celebrate companies pushing the global power sector forward, and this year’s results underscore ZincFive’s accelerating leadership.

The wins reflect the company’s momentum as demand for high-power, low-impact energy storage solutions continues to intensify. With nearly 2 gigawatts of nickel-zinc (NiZn) systems deployed or contracted worldwide, ZincFive is helping operators meet the explosive requirements of AI-driven data centers while strengthening resilience and reducing environmental impact.

At the center of this progress is ZincFive’s Immediate Power Solutions portfolio, which blends patented NiZn chemistry with intelligent system-level engineering. These systems deliver millisecond-level responsiveness to dynamic loads and operate reliably at higher temperatures, reducing cooling requirements and improving overall efficiency. The award-winning BC 2 AI UPS Battery Cabinet extends this approach even further, providing fast-load support for GPU-intensive AI applications and traditional outage protection in a single compact system. By consolidating functions that once required multiple layers of equipment, it frees valuable white space and simplifies power architecture.

ZincFive’s wins also reinforce the company’s long-standing commitment to safety and sustainability. NiZn technology is inherently safe, built from abundant, recyclable materials and provides lifetime greenhouse gas emissions that are 25 to 50 percent lower than traditional lead-acid and lithium-ion options. This aligns with growing industry expectations for cleaner, more responsible power infrastructure.

These latest honors join a growing list of accolades, including recent recognition on TIME’s 2025 World’s and America’s Top GreenTech Companies lists, the 2024 Edison Award™, CleanTech Breakthrough’s 2024 Overall Innovation of the Year, and more, signaling a defining moment for ZincFive as it continues to set new benchmarks in mission-critical power.

To learn more, reach the full release here.

The post ZincFive Earns Four Wins at the 2025 Power Technology Excellence Awards appeared first on Data Center POST.

As artificial intelligence accelerates across global data centers, conversations often focus on compute, power density, and next-generation infrastructure. But according to Nabeel Mahmood, Strategic Advisor at ZincFive and Brandon Smith, Vice President of Global Sales and Product at ZincFive, the most crucial element of AI scalability isn’t hardware. It’s people.

Moderated by Ilissa Miller, CEO of iMiller Public Relations, this webinar uncovered why the AI workforce, not compute, is the true limitation and what must change for sustainable growth.

People Are the Real Bottleneck in AI Scalability

Mahmood explained that scaling AI isn’t just a matter of adding more servers or GPUs. It requires practitioners who understand data pipelines, model governance, operational resiliency, and infrastructure design. Without skilled talent, organizations face operational risks despite abundant compute. Smith highlighted that AI and machine learning job postings have increased significantly, noting a recent figure showing a 450 percent rise, far outpacing available expertise.

Technical Silos Are Creating a New Skills Crisis

The discussion emphasized a growing gap across disciplines. Electrical, mechanical, IT, and data science teams frequently operate in isolation despite the interdependent nature of modern AI data centers. This fragmentation leads to delays, inefficiencies, and architectures unable to handle today’s dynamic workloads. Smith described the shift from traditional “white space versus black space” to today’s “blended gray space”, where cross-functional knowledge is essential. Mahmood added that the inability to transfer knowledge horizontally and vertically across teams is a major obstacle to scaling AI systems.

Energy Innovation Is Essential for AI Expansion

AI’s spiking, unpredictable workloads challenge a grid that was never designed for ultra-dense compute. Mahmood and Smith both pointed to advanced energy storage solutions, including ZincFive’s high-power nickel-zinc technology, as the key to unlocking performance. These innovations smooth electrical spikes, maximize usable capacity, and support emerging off-grid compute models that reduce dependence on constrained utilities.

Preparing the Future AI Workforce

Both speakers agreed that organizations must treat talent as core infrastructure. That means forecasting future skills, investing in upskilling programs, partnering with universities, and fostering environments where engineers can innovate across disciplines. As Smith noted, the strongest teams of tomorrow will be adaptive, coachable, and ready to evolve alongside rapidly changing AI infrastructure demands.

Watch the webinar below:

The post Why AI Still Needs People: The Workforce Behind the Machines appeared first on Data Center POST.

As AI adoption accelerates worldwide, power infrastructure has become one of the biggest constraints for data center growth. ZincFive, a global leader in nickel-zinc (NiZn) battery technologies, has taken a major step in meeting this challenge with the close of an oversubscribed $30 million Series F funding round. The investment brings total capital raised to $254 million since 2016 and will enable rapid expansion in manufacturing and commercial scale.

Backed by leading climate and industrial investors including Helios Climate Ventures, Climate Investment (CI), Japan Energy Fund, General Ventures, and Clear Creek Investments, ZincFive has already deployed or contracted nearly 2 GW of nickel-zinc backup cabinets across the global data center sector. This milestone reflects both the maturity of its technology and the confidence of hyperscalers and operators seeking safe, sustainable power alternatives.

The funding announcement follows the launch of BC 2 AI, the first nickel-zinc UPS battery cabinet engineered for AI-driven data centers and their dynamic power requirements. With zero thermal-runaway risk, AI load support, and a 96 percent recyclable design, BC 2 AI demonstrates ZincFive’s commitment to continuous improvement from core chemistry to full system architecture.

A Sustainable, Proven Alternative

ZincFive’s patented NiZn chemistry provides high power density, inherent safety, minimal maintenance requirements, and an industry-leading environmental footprint compared to lithium-ion and lead-acid systems. With nearly a decade of proven field performance and expanding OEM partnerships, ZincFive continues to advance its role in next-generation, AI-ready power architectures.

With AI infrastructure driving one of the largest build cycles in modern history, ZincFive’s Series F funding marks a pivotal moment. The company is now positioned to scale production, deepen its commercial reach, and power the safe, sustainable data center ecosystems required for the AI era.

To read the full press release, visit here.

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