How Waterless Manufacturing Is Making EV Batteries Cheaper

Electric vehicles are becoming increasingly popular, but one major barrier to widespread adoption remains: cost. At the heart of this challenge lies the battery—specifically the cathode, which accounts for a staggering 60% of both battery costs and carbon footprint. In a recent GreenTech Pulse podcast episode, Virginia Klausmeier, CEO of Sylvatex, revealed how her company’s innovative waterless manufacturing process is revolutionizing EV battery production by cutting costs by up to 25% while dramatically reducing environmental impact.

The Battery Challenge: Why Cathodes Matter

“We’re at the beginning portion of the largest energy transition that’s going to happen for our lifetime,” Klausmeier explains. With batteries powering both electric vehicles and energy storage systems for renewable energy, their production efficiency directly impacts the viability of the clean energy revolution.

Currently, most battery materials are mined globally, refined and manufactured primarily in China, then shipped worldwide. This dispersed supply chain increases costs and carbon emissions. The cathode—the positive part of the battery—represents the biggest opportunity for improvement as it constitutes the majority of battery costs.

The Waterless Solution: A Manufacturing Revolution

Traditional cathode manufacturing involves multiple water-intensive steps:

1. Mixing metal nanoparticles in water
2. Co-precipitating the material
3. Adding lithium
4. Applying high heat (calcining)

This process produces significant wastewater, sodium sulfate waste, and requires substantial energy.

Sylvatex’s approach is radically different:

1. All components go into a single pot
2. A small amount of organic additive serves as a catalyst
3. The material undergoes a single calcining step
4. The catalyst burns off completely during heating

The result? A process that:

• Uses zero water
• Produces no wastewater or sodium sulfate waste
• Reduces energy intensity by 80%
• Cuts production costs by 20-25%
• Allows for more flexible feedstock options, including recycled materials

The Real-World Impact: Billion-Dollar Savings

The financial implications are substantial. “If Tesla used our process to make the NMC in their Cybertrucks last year, it would have saved them a billion dollars,” Klausmeier notes. This translates to approximately $1,000 per vehicle and a 10% increase in profit margin—without changing vehicle design or battery chemistry.

For home energy storage systems like solar setups, where batteries represent the largest cost component, this technology could significantly improve affordability and adoption rates.

Beyond Cost: Environmental Benefits and Regional Production

The environmental benefits extend beyond cost savings. Traditional cathode production creates heavily polluted wastewater that poses permitting challenges outside China. By eliminating water use entirely, Sylvatex’s process removes this barrier to regional manufacturing.

This regional approach is critical for several reasons:

1. Reduced carbon footprint: Shorter supply chains mean less transportation emissions
2. Energy security: Less dependence on single-source regions
3. Economic benefits: Job creation and value retention within local economies
4. Scale: Meeting global demand requires production facilities worldwide

“The US produces almost zero metric tons [of cathode material] and we need to produce something like 900 metric tons in the next few years to meet demand,” Klausmeier explains. “Each plant usually is about 50 metric tons at most, so that’s like 20 plants that need to be built real quick.”

The Future of Battery Manufacturing

Looking ahead, Klausmeier identifies three major trends in EV battery technology:

1. Regionalized supply chains: Every major global region will develop its own battery production ecosystem
2. Advanced manufacturing techniques: Innovation in production processes, not just battery chemistry
3. Diversified feedstocks: Increased recycling and regional sourcing of raw materials

For Sylvatex, the goal is clear: bring their technology to market in a way that ensures end consumers—not just material producers—benefit from the cost savings. This means working directly with OEMs and integrating into the supply chain strategically.

Lessons for Green Technology Entrepreneurs

When asked about lessons learned as a green tech entrepreneur, Klausmeier offers powerful advice: “Swing for the fences. No one else is doing stuff—you have to do it.”

For those looking to make their own impact in sustainable technology, she recommends:

1. Outline what you think will be game-changing
2. Research who’s already working in that space
3. If there’s a gap, consider filling it
4. If others are already there, find ways to support their efforts

A Cleaner, More Affordable Electric Future

Waterless cathode manufacturing represents a perfect alignment of economic and environmental benefits. By making batteries significantly cheaper while eliminating waste and reducing energy use, companies like Sylvatex are addressing multiple challenges simultaneously.

For consumers concerned about the high cost of EVs or home energy storage systems, innovations like these offer hope that clean energy technologies will become increasingly affordable and accessible. As regional production scales up and manufacturing processes improve, we can expect to see continued price reductions and environmental benefits throughout the clean energy ecosystem.

Want to learn more about Sylvatex’s revolutionary approach to battery manufacturing? Visit sylvatex.com or connect with Virginia Klausmeier on LinkedIn.