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Battery, Battery Materials

<2025> Latest Trends in Single Crystal (Single Particle) Cathode Technology Development and Market Outlook

 

 

 

With the trend toward higher energy density in lithium-ion batteries, securing structural stability and long cycle life of cathode materials has emerged as a critical challenge. In particular, as the commercialization of high-nickel (Ni ≥ 80%) ternary cathode materials (NCM, NCA) expands, single-crystal cathode technology that can enhance the durability of their crystal structures is gaining attention.

 

Conventional polycrystalline cathode materials have numerous grain boundaries, making them prone to cracking under electrochemical stress during charge and discharge. They also exhibit higher reactivity with electrolytes, leading to accelerated degradation. In contrast, single-crystal cathodes consist of individual particles, significantly reducing interfacial issues and offering superior structural stability and cycle life. Especially under repeated cycling, they experience fewer internal cracks or particle fractures, making them well suited for high-cycle applications such as electric vehicles (EVs).

 

Currently, the cathode materials used in commercial electric vehicle batteries have a polycrystalline structure composed of numerous metal compound crystals. During the calendering process that shapes the cathode active material into a uniform thickness, as well as throughout charge and discharge cycles, cracks can easily form between particles. As charging and discharging repeat, these cracks widen, leading to material degradation. Such particle cracking increases gas generation inside the battery, reduces the number of charge-discharge cycles, and ultimately shortens battery life.

 

In contrast, single-crystal materials do not fracture easily, significantly mitigating these issues. Additionally, as the nickel content in cathode materials is increased to boost capacity, structural stability declines and the risk of thermal runaway rises. This has amplified the need for the development of single-crystal cathodes as a solution.

 

Single-crystal cathode materials can also reduce processing costs and improve production yield. This is because they generate little to no debris, lowering the probability of defects, and do not require a washing process. Washing is an essential step in conventional cathode material production, in which impurities are removed using water.

 

Once commercialized, single-crystal cathode materials are expected to accelerate the adoption of high-nickel cathodes. Reduced gas generation leads to longer battery life and allows for a higher active material loading, ultimately increasing energy density. When applied to EV battery packs, this means achieving a driving range of over 500 km per charge with fewer battery cells. It also enables automakers to expand their lineups with long-range models. In this sense, single-crystal cathodes could be a game-changer that delivers both cost reduction and performance improvement.

 

However, single-crystal cathodes are not without drawbacks. In the past, the industry focused on polycrystalline cathodes because large-particle single crystals had high initial resistance, making it difficult to apply the desired voltage. This prevented proper output and hindered performance improvements.

 

In addition, extra processing steps are required, and their higher operating voltage can increase battery temperature. During the electrode fabrication process, especially in the calendering stage, single-crystal particles may be damaged. As a result, early mass production is expected to involve blending single crystals with polycrystalline materials rather than using pure single crystals.

 

Recent research and development efforts have focused on key topics such as controlling the size of single-crystal particles, achieving uniform particle distribution, ensuring crystal stability at high nickel content, and surface modification through coating and doping technologies. For example, active attempts are being made to improve both capacity and cycle life by applying doping techniques using elements such as Zr, W, and Al to single-crystal NCM811 and NCM90 cathode materials. In addition, heat treatment technologies are advancing to secure structural stability even at high temperatures.

 

From a commercialization perspective, reducing the synthesis cost of single-crystal cathode materials has emerged as a key challenge. In response, the development of mass-production technologies using high-efficiency hydrothermal synthesis and continuous flow reactor systems is underway. This trend is further supported by precise control in precursor synthesis, shape control of primary and secondary particles, and automation of the coating process.

 

Chinese companies are already producing single-crystal cathode materials based on NCM523 and 622, while South Korean cathode manufacturers such as LG Chem, Ecopro BM, L&F, and POSCO Future M are also gradually expanding the use of high-reliability single-crystal cathodes. Notably, leading EV companies like Tesla consider high-nickel single-crystal cathodes as strategic materials to enable fast charging and ensure high-temperature stability, and are strengthening supply agreements with related partners. Currently, a few leading Chinese companies dominate over 70% of the market for mass-produced single-crystal cathode materials.

 

According to announcements from South Korean cathode material companies, sample provision began in 2023, and SNE Research projects that production will reach approximately 50,000 tons by 2025. In China, among ternary single-crystal cathode materials, 5-series products such as NCM523 account for the highest share at 60–70%. Single-crystal NCM622 and other 6-series materials represent around 18–25%, while 8-series materials with nickel content of 80% or more have seen growing production since 2021 and currently account for about 15%. This share is expected to continue increasing.

 

 

 

Strong Point of This Report

 

① Coverage of fundamentals and recent advances in single-crystal Ni-based cathode material development

 

Detailed research trends and future outlook for single-crystal Ni-rich cathode materials

 

Studies on capacity degradation mechanisms of single-crystal Ni-rich cathodes

 

Market outlook for single-crystal NCM cathode materials in Korea and China (through 2035)

 

In-depth analysis of recent development trends and patents of single-crystal cathode material manufacturers

 

  ⑥ Overview of national programs related to single-crystal cathode material development

 

 

 

Figure. Schematic of synthesis and additional modification processes for single-crystal (single-particle) Ni-based layered cathode materials

 

 

 

 

Figure. Improvement of structural stability and prevention of interparticle cracking through boron doping

 

 


Contents

 

 

 

1. Overview of Cathode Materials 13

 

   1.1. History of Cathode Material Development 13

 

   1.2. Recent Trends Surrounding Cathode Materials 14

 

    1.2.1. Layered Oxide Cathode Materials 14

 

    1.2.2. Spinel Oxide Cathode Materials 15

 

    1.2.3. Polyanionic Oxide Cathode Materials 16

 

   1.3. Current Status of Cathode Material Development 18

 

    1.3.1. Microstructure Modification 19

 

    1.3.2. Elimination of Cathode Cracks 20

 

     1.3.2.1. Polymer Coating for Cathode Crack Elimination 20

 

     1.3.2.2. Suppression of Crack Formation Through Grain Boundary Modification Within Secondary Particles 20

 

    1.3.3. Application of One-Pot Process 21

 

    1.3.4. Microwave Treatment 22

 

 

 

2. Research Trends and Future Outlook of Single-Crystal Ni-Rich Layered Cathode Materials 23

 

   2.1. Necessity of Research on Single-Crystal Ni-Rich Layered Materials 24

 

    2.1.1. Reasons for the Need for Ni-Rich Layered Materials (Advantages) 24

 

    2.1.2. Degradation Mechanism of Ni-Based Layered Cathode Materials 28

 

    2.1.3. Necessity of Single-Crystallization (Single-Particle Formation) of Ni-Based Layered Cathode Materials 31

 

   2.2. Definition of Single-Crystal Cathode Materials 32

 

   2.3. Current Status of Single-Crystal Cathode Material Technology Development 33

 

    2.3.1. Research on the Synthesis of Single-Particle Ni-Based Layered Materials 33

 

    2.3.2. Research on Sintering Methods for Synthesizing Single-Particle Ni-Based Layered Materials 40

 

    2.3.3. Material Modification for Performance Improvement of Single-Particle Ni-Based Layered Materials 47

 

     2.3.3.1. Surface Coating 48

 

     2.3.3.2. Element Substitution (Doping) 50

 

      2.3.3.2.1. Single Doping 52

 

      2.3.3.2.2. Dual Doping 54

 

     2.3.3.3. Electrolyte Optimization 55

 

    2.3.4. Utilization Strategies for Single-Particle Ni-Based Layered Materials 56

 

     2.3.4.1. Advantages of Single-Particle Formation in Electrode Design 57

 

     2.3.4.2. Disadvantages of Single-Particle Formation in Electrode Design 58

 

     2.3.4.3. Research on Solving Issues of Single-Particle Formation in Ni-Based Layered Materials 58

 

   2.4. Improvements Through Single-Particle Materials 59

 

    2.4.1. Mitigation of Particle Fracture 59

 

     2.4.4.1. Pressing Step in Electrode Manufacturing Process 59

 

    2.4.2. Particle Fracture During Charge and Discharge 60

 

    2.4.3. Quantitative Reduction of Surface Degradation by Reducing Specific Surface Area 61

 

    2.4.4. Increase in Energy Density 63

 

    2.4.5. Possibility to Omit Washing Process 64

 

   2.5. Limitations of Current Single-Crystal Cathode Material Technology Development and Related Research 65

 

    2.5.1. Structural Degradation Due to Difficulties in Optimizing Synthesis Conditions 65

 

    2.5.2. Limitations in Particle Size 66

 

 

 

3. Development of Single-Crystal Ni-Based Cathode Materials: Fundamentals and Advances 67

 

   3.1. Overview 67

 

   3.2. Ni-Based Cathode Materials 70

 

    3.2.1. Chemical Structure 70

 

    3.2.2. Electronic Structure 72

 

   3.3. Challenges of Ni-Based Layered Oxides 74

 

    3.3.1. Synthesis Difficulties 74

 

    3.3.2. Structural Instability 76

 

    3.3.3. Chemical Instability 77

 

    3.3.4. Mechanical Performance Degradation 80

 

    3.3.5. Safety Issues 82

 

   3.4. Origin of Single-Crystal Ni-Based Layered Oxides 84

 

    3.4.1. Particle Engineering Effects and Performance Comparison of Single-Crystal Cathode Materials 86

 

    3.4.2. Battery Performance Enhancement Strategies Using Single-Crystal Materials 89

 

    3.4.3. Concept and Advantages of Single-Crystals in Battery Materials 90

 

   3.5. Synthesis of Single-Crystal Ni-Based Layered Oxides 90

 

    3.5.1. Synthesis Methods 90

 

    3.5.2. Synthesis and Characterization of Single-Crystal Cathode Active Materials 99

 

    3.5.3. Various Solid Formation Mechanisms and Fabrication Methods of Single-Crystal Oxides 101

 

   3.6. Comparative Study Between Single-Crystalline and Polycrystalline Materials 103

 

    3.6.1. Battery Safety and Electrochemical Performance of Single-Crystal Cathode Materials 105

 

   3.7. Latest Processing Techniques for Single-Crystal Ni-Based Cathode Materials 108

 

    3.7.1. Doping and Surface Coating 108

 

    3.7.2. Mechanical Studies 110

 

   3.8. Results and Conclusion 113

 

 

 

4. Study on Capacity Degradation Mechanism of Single-Crystal Ni-Rich NCM Cathodes 116

 

   4.1. Overview 116

 

   4.2. Evaluation of Basic Properties of Single-Crystal and Polycrystalline Ni-Rich Cathodes 117

 

    4.2.1. Synthesis of Single-Crystal and Polycrystalline Cathode Materials 118

 

    4.2.2. Composition and Analysis of Single-Crystal and Polycrystalline Cathode Materials 119

 

    4.2.3. Electrochemical Properties of Single-Crystal and Polycrystalline Cathode Materials 122

 

     4.2.3.1. Comparative Analysis of Rate Capability and Degradation Mechanism of Single-Crystal and Polycrystalline Cathodes 124

 

    4.2.4. Structural Stress Analysis of Single-Crystal and Polycrystalline Cathode Materials 124

 

    4.2.5. In-situ XRD Analysis of Single-Crystal and Polycrystalline Cathode Materials 128

 

    4.2.6. TEM Analysis of Single-Crystal and Polycrystalline Cathode Materials 132

 

    4.2.7. Results and Conclusion 134

 

 

 

5. Synthesis and Modification of Single-Crystal NCM Cathode Materials: Growth Mechanism 136

 

5.1. Overview 136

 

5.2. Growth Mechanism (Considerations for NCM Cathodes) 137

 

 5.2.1. Thermodynamics and Growth Mechanism of Single-Crystal NCM Cathodes 137

 

5.3. Solid-State Reaction 139

 

5.4. Solid–Liquid Rheological Reaction 140

 

5.5. Crystal Growth in Molten Salt Flux 141

 

5.6. Modification of Morphology 142

 

 5.6.1. Shape Control 143

 

 5.6.2. Facet Control 144

 

 5.6.3. Conclusion 144

 

 

 

6. Particle Control of Single-Crystal Ni-Rich Cathode Materials (Application of Sintering Additives) 146

 

   6.1. Overview 146

 

   6.2. Experiment: Strategic Approach 146

 

   6.3. Experimental Results 147

 

    6.3.1. Optimization of Sintering Additives for Promoting Crystal Growth 147

 

    6.3.2. Crystal Growth Mechanism 149

 

    6.3.3. Structure of Single-Crystal Ni-Rich Cathode Materials 151

 

    6.3.4. Performance of Single-Crystal Ni-Rich Cathode Materials 156

 

     6.3.4.1. Microstructure Control Strategy for High-Density Electrode Design 160

 

     6.3.4.2. Pouch Cell Performance Evaluation and Characterization 161

 

   6.4. Results of Sintering Additive Application 164

 

 

 

7. All-Dry Synthesis of Single-Crystal NCM Cathode Materials 166

 

   7.1. Overview 166

 

    7.1.1. Review of the Manufacturing Process for Single-Crystal Ni-Rich NCM Cathode Materials 166

 

   7.2. Dry Synthesis 168

 

   7.3. Results and Discussion of Dry Synthesis 170

 

    7.3.1. Structure and Morphology of Precursors 170

 

    7.3.2. Effect of Sintering Conditions on NCM Formation 172

 

     7.3.2.1. Electrochemical Performance of Single-Crystal NCM1–3 174

 

    7.3.3. Single-Crystal NCM from Ball-Milled Precursors 176

 

    7.3.4. Conclusion 180

 

 

 

8. One-Spot Synthesis of Single-Crystal NCM523 Cathode Materials 182

 

   8.1. Overview 182

 

   8.2. Synthesis of NCM523 183

 

   8.3. Characterization of Materials 185

 

   8.4. Electrochemical Properties 185

 

   8.5. Experimental Results and Discussion 186

 

    8.5.1. Analysis of Synthesized Cathode Materials 186

 

    8.5.2. Electrochemical Properties of Cathode Materials 190

 

    8.5.3. Conclusion 194

 

 

 

9. Synthesis and Modification of Single-Crystal NCM9073 Cathode Materials 195

 

   9.1. Overview 195

 

   9.2. Experimental Design and Analytical Methods 195

 

    9.2.1. Synthesis and Modification Methods of Single-Crystal NCM9073 Materials 195

 

    9.2.2. Physical Property Analysis 196

 

    9.2.3. Evaluation of Electrochemical Performance 197

 

   9.3. Results and Interpretation of Zn Surface-Concentrated Doping 198

 

     9.3.1. Interpretation of Physical Property Analysis of Zn Surface-Concentrated Doped Single-Crystal NCM9073 198

 

     9.3.2. Evaluation of Electrochemical Performance of Zn Surface-Concentrated Doped Single-Crystal NCM9073 204

 

     9.3.3. Electrochemical Performance and Property Changes Under High Temperature (60°C) Conditions 209

 

     9.3.4. Thermal Stability Evaluation of Zn Surface-Concentrated Doped Single-Crystal NCM9073 213

 

 

 

10. Market Size and Outlook of Single-Crystal Cathode Materials 214

 

    10.1. Market Overview and Growth Drivers of Single-Crystal Cathode Materials 214

 

     10.1.1. Regional M/S of Single-Crystal Cathode Materials 214

 

     10.1.2. M/S by Type of Single-Crystal Cathode Materials 214

 

     10.1.3. Key Applications, Market Trends, Opportunities, Constraints, and Challenges 215

 

     10.1.4. Demand Trends and M/S Changes in the Single-Crystal Cathode Market 216

 

    10.2. Market Size and Outlook of China's Single-Crystal High-Nickel Ternary Cathode Industry 218

 

     10.2.1. Overview of China’s Single-Crystal High-Nickel Ternary Cathode Industry 218

 

     10.2.2. Market Size Analysis of China’s Single-Crystal High-Nickel Ternary Cathode Materials 219

 

     10.2.3. Supply and Demand Analysis of China’s High-Nickel Ternary Single-Crystal Cathode Materials 222

 

     10.2.4. Comparison Between Global and Chinese Markets for High-Nickel Ternary Single-Crystal Cathode Materials 224

 

    10.3. Production Forecast of Ternary Single-Crystal Cathode Materials in Korea and China (2019–2035) 226

 

    10.4. Production and Market Outlook of Ternary Single-Crystal Cathode Materials in Korea (2019–2035) 226

 

    10.5. Production and Market Outlook of Ternary Single-Crystal Cathode Materials in China (2019–2035) 227

 

    10.6. ASP Trend of Ternary Single-Crystal Cathode Materials (2019–2035) 227

 

    10.7. M/S Forecast by Ternary Single-Crystal Cathode Type in China (2019–2035) 228

 

    10.8. Market Outlook by Ternary Single-Crystal Cathode Type in China (2019–2035) 228

 

 

 

11. National Programs for Single-Crystal Cathode Material Development 229

 

     11.1. U.S. DOE Program 229

 

      11.1.1. Production of Ni-Rich Single-Crystal Cathode Materials via Ultrafast Hydrothermal Method 229

 

      11.1.2. Scale-Up of High-Performance Ni-Rich Single-Crystal Cathode Materials 234

 

      11.1.3. Single-Crystal Cathode Materials for High-Performance All-Solid-State LIBs 236

 

     11.2. EU Program 240

 

      11.2.1. LIBEST2 Project 241

 

      11.2.2. FutureCat Project 242

 

     11.3. Korea National R&D Program 244

 

     11.4. Japan National R&D Program 246

 

      11.4.1. Creation of High-Energy-Density Cathode Materials via Low-Crystallinity Control 246

 

      11.4.2. Solving Problems Through Material Design & Creation 247

 

 

 

12. Patent Analysis of Single-Crystal Cathode Material Companies 249

 

    12.1. Tesla 249

 

    12.2. LG Chem 250

 

    12.3. SM Lab 256

 

    12.4. Nano One Materials 260

 

    12.5. POSCO Future M 264

 

    12.6. Cosmo Advanced Materials & Technology 268

 

    12.7. L&F 273

 

    12.8. Easpring 276

 

    12.9. BASF Shan Shan 278

 

    12.10. GEM 281

 

    12.11. XTC (Xiamen Tungsten) 284

 

    12.12. Henan Kelong 289

 

    12.13. Hyundai/Kia Motors 292

 

    12.14. 6K Inc. 294

 

    12.15. Dynanonic 297

 

    12.16. Suzhou Long Power 300

 

    12.17. Fengchao Energy 303

 

    12.18. Ecopro BM 306

 

    12.19. Umicore 309

 

 

 

13. Industry Trends of Single-Crystal Cathode Material Companies 312

 

    13.1. LG Chem 318

 

    13.2. POSCO Future M 321

 

    13.3. Ecopro BM 326

 

    13.4. Geumyang (SM Lab) 329

 

    13.5. L&F 331

 

    13.6. Cosmo Advanced Materials & Technology 335

 

    13.7. Umicore 338

 

    13.8. Sumitomo Metal Mining 340

 

    13.9. Toda Kogyo 342

 

    13.10. Guizhou Zhenhua E-Chem (ZEC) 344

 

    13.11. Chanyuan Lico 349

 

    13.12. Ronbay 354

 

    13.13. XTC (Xiamen Tungsten) 358

 

    13.14. Tianjin B&M 362

 

    13.15. Easpring 366

 

    13.16. Reshane 372

 

    13.17. Yibin Libode 376

 

    13.18. Wanxing 123 378

 

    13.19. GEM 383

 

References             393

 

 

 

 

 

 

 

 

 

 

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