<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
②
Detailed research trends and future outlook for single-crystal
Ni-rich cathode materials
③ Studies
on capacity degradation mechanisms of single-crystal Ni-rich cathodes
④ Market outlook for
single-crystal NCM cathode materials in Korea and China (through 2035)
⑤ 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