Single Crystal Cathode Materials for Lithium-Based Batteries: Synthesis, Scaleup, and Manufacturing

Monocrystalline solids have been broadly used in many fields, including batteries, electronics, and optics. Monocrystalline cathode materials have regained intensive study in recent years because of their potential to stabilize the cathode-electrolyte interphase at elevated voltages and/or reduce gassing from high capacity nickel-rich cathode materials; thus, more energy can be extracted from the same materials, except that they are converted into grain boundary-free particles, or so-called "single crystals" in the battery field. This work reviews the history, current progress, and future trends of single crystal cathodes for lithium-based batteries with a focus on cost-effective synthesis, scaleup, and manufacturing. Much work is needed to reduce manufacturing costs of single crystal cathodes, from the selection of precursors and synthesis routes to morphology control and equipment design. This review highlights the importance of cost-oriented fundamental research and processing science to accelerate battery materials manufacturing and establish a resilient manufacturing chain for versatile energy storage technologies.