Key Insights from The Battery Show 2024 from EMS

The buzz of a lively tradeshow

A few weeks ago, EMS had the pleasure of being one of the many exhibitors at The Battery and EV Expo in Detroit, Michigan.

The 14th annual Battery Show North America was held in Hunting Place and boasted historic numbers, highlighting the importance of upgrading venues from last year’s event which had also record numbers of exhibitors and attendees.

The Battery Show 2024 saw 21,000 professionals, 1,250 exhibitors (the most since the show launched in 2010), and over 200 keynote speakers, discussing a range of interesting topics.

While there were many important topics, one seemed to stand out from the crowd: The future of the battery industry.

The Future of the Battery Industry

The battery industry has been a growth industry for decades, with each year bringing a larger increase than the year before. As the demand for battery-hungry things like electric vehicles, drones, personal electronics, and energy storage solutions continues to grow, so will the battery industry.

Governments around the world, from the U.S. to the EU and China, are setting aggressive targets for EV adoption and sustainable energy solutions, further driving the battery industry’s growth.

The global battery market is expected to grow at a CAGR (Compound Annual Growth Rate) of 16.45% from 2024 to 2032, reaching a staggering 424 billion by 2030, fourfold the market total in 2021.

So much of the future depends on adopting sustainable, scalable battery solutions equal to the hungry power that fuels innovation. 

Being an exhibitor at the Battery Show for several years has given us here at EMS a unique, deep-dive look into the industry and where it’s headed. 

Rows of batteries in colored wrapping, highlighting EMS's focus on consistent, high-quality battery production

EVs and Energy Storage

Electric Vehicles (EVs) and Energy Storage Systems (ESS) were popular topics at The Battery Show, ranging from keynote speeches at the Battery Theater to business lunches in the bustling cafeteria. Battery technology innovations are driving more efficient, sustainable, and scalable EVs and increasing the potential of energy storage systems, which are desperately needed if the battery industry wants to continue to grow.

The Growth of Electric Vehicles

By 2030, the global electric vehicle market is projected to reach over $820 billion, propelled by increased environmental regulations, consumer demand, and advancements in battery technology. Batteries are at the heart of EVs. As the battery industry improves, so too does the potential of what EVs can do.

Just in the last several years, we’ve seen how battery technology innovations have helped create EVs with faster charger time and longer ranges at a cheaper price point. These continued improvements have primed EVs for mass adoption worldwide, fueled by independent demand and the growing demand from governments pushing progressive regulations.

Energy Storage Systems (ESS)

Energy storage systems are an integral support we need if the battery industry is expected to continue to grow.

With several favorable government policies like the Federal Energy Regulatory Commission’s (FERC) mandating the integration of energy storage resources into the grid, ESS are experiencing an accelerated market expansion. Technological advancements, like what we see with lithium-ion batteries, have led to a drastic reduction in cost with an equally drastic increase in performance.

Battery Innovations for EVs

Innovations in the EV space can take many forms- from better ways to mine materials to using AI to ensure the most streamlined manufacturing processes. With such a large market, seemingly disconnected innovations all come together to create drastic changes in price (lower) and quality (higher).

This is a self-propelling prophecy of sorts. As EVs improve, offering faster charge times, longer ranges, and more affordable costs, more people go from gas and hybrids to EVs, furthering more developments and capabilities.

Thermal Management in EV Batteries

Thermal management is one of the biggest engineering challenges in EV battery design and innovation. As battery packs become more energy-dense, controlling temperatures becomes both more complicated and vital.

At the Battery Show, there were numerous discussions about managing heat in EV battery systems, including liquid cooling methods, phase-change materials, and integrated cooling channels. These thermal management solutions will continue driving battery technologies, paving the way for continued advancements.

Energy Storage and the Grid

Growing the battery industry depends wholly on expanding energy-storing systems and the grid. With a grid that can handle increasing amounts of energy demand, there is nothing preventing battery innovations.

But should there be a lacking foundation, battery innovations will be wasted. New ESS and grid solutions were essential topics of discussion at the battery show, underlining their importance for the future of the battery industry.

Sustainability in EV and ESS Batteries

One major discussion at the Battery Show 2024 was sustainability in EV and Energy Storage Systems. Obviously, a big advantage of the battery industry is that it’s more environmentally friendly than fossil fuels. But that isn’t always the case- sometimes, how we collect and transport battery materials produces excessive waste.

If the battery industry is expected to grow, we need to find more sustainable ways to produce, manufacture, and transport battery and battery materials.

Another huge addition to the sustainability of EVs and ESS is our ability to efficiently recycle batteries and their materials. With new, innovative ways to recycle materials, we’re equipped for the future growth of the battery industry. Every year, we make every aspect of the battery industry more sustainable, and these discussions are a bigger reason for this.

Real-World Applications 

The discussions at the Battery Show also highlighted real-world case studies of how EVs and energy storage systems are being implemented across industries. From electric buses reducing emissions in urban areas to large-scale ESS installations stabilizing grids during peak demand, the future of energy storage is not just theoretical—it’s happening now. Engineers and manufacturers must continue to push the boundaries of what’s possible with battery technology to meet the growing demands of an electrified world.

AI and the Battery Industry

A robotic hand reaching toward a neural network grid, representing the reach of AI in the Battery Industry | EMS

A frequently discussed topic at The Battery Show, whether on the stage, at booths, or on the floor, was AI’s current and future role within the battery industry.

AI already has many uses, from creating better shipping processes to finding improvements for gathering materials. Still, every year, there are more and more innovations in what AI can do to help grow the battery industry. 

If the battery industry is expected to continue its meteoric rise, AI will have to play a bigger role- whether it’s improving charging methods, discovering more efficient manufacturing processes, or improving how we recycle and reuse low-supply materials.

Optimized Charging

AI algorithms are being developed to optimize charging speeds based on battery usage patterns, helping reduce costs and increasing longevity. Presently, companies like Tesla use AI to manage and optimize charging behavior. In time, AI can continue to prolong battery life by adjusting charging speeds and predicting the best times to charge based on energy demand and availability.

Discovery of Battery Materials

Discovering new materials and compounds that are more efficient, affordable, and sustainable is made better with machine learning algorithms driven by AI. Several materials we rely on right now for batteries are in short supply. The more we mine those supplies, the more expensive batteries will become. With AI, we can find more sustainable, long-term materials and compounds that will help propel the battery industry in the years to come.

Battery Design

AI plays a massive role in better battery designs. Using AI simulations, engineers can assess the performance of different designs before they are ever physically built, saving companies time and money while allowing for more advanced innovations. For example, AI has been used to design more efficient batteries that are just as powerful as other batteries while using 70% less lithium in its creation.

Battery Recycling

Another area where AI shines is with recycling batteries. AI can identify, sort, and recover valuable materials from used batteries more efficiently than we’ve done in the past. This is imperative for growing the battery industry as it directly reduces the amount of raw materials that need to be extracted. These raw materials can be quickly reintroduced into the manufacturing process, keeping up our production capabilities to stay in line with demand.

Environmental Impact

Relying on batteries should be having positive effects on our environment. But in a sad swing of fate, the more we rely on batteries, the more costly it is on our environment. Whether its rare material extractions or high amounts of waste, batteries aren’t yet the salvation we all want it to be. Luckily, AI is proving to be a very effective tool in making batteries more environmentally friendly than ever before. From more efficient recycling methods to increasing battery lifespan, AI has been making big differences in the efficiency of batteries, reducing their environmental impact.

Drones and Personal Electronics

Drones and personal electronics are both rapidly growing markets.

With these technologies becoming increasingly central to daily life and specialized fields, advancements in battery technology are necessary to meet the rising needs.

Energy efficiency, longevity, and durability need to keep expanding to meet the needs of these growth markets.

At the Battery Show, EMS had several exciting conversations about how our thermal management solutions can be used to improve the effectiveness of battery systems in drones and personal electronics.

 

Close-up of a drone in flight, showcasing advancements in battery-powered technology for electronics | EMS

Battery Density and Weight Reduction

Battery weight and density are critical concerns in the drone and personal electronics markets, where devices must be lightweight while offering extended power. Weight reduction is crucial for drones as it directly affects flight time, maneuverability, and payload capabilities. Companies are working on developing higher energy-dense batteries that are lightweight yet capable of longer operating times. As battery materials and designs become better, drones and personal electronics become more advanced, unlocking improved performance and longevity.

Quick-Charge Technologies

As electronic devices grow in demand and use, the demand for quick-charge technologies also grows. Advances in battery design, like using clad cell connectors, can improve electrical and thermal conductivity. Better-designed and manufactured batteries allow us to have faster-charging smartphones, laptops, and drones without excessive heat generation or degradation.

Battery Life Cycle and Durability

Increased durability in electronics is becoming more critical as we rely more on drones and personal electronics. This is especially true in intense or professional environments. New technologies are being developed that extend the lifespan of batteries and make batteries resilient to frequent charging cycles. Battery Management Systems (BMS) improvements also increase battery durability by regulating temperature, voltage, and charge levels to reduce wear.

AI and Predictive Maintenance

AI has become essential for optimizing battery health and longevity in drones and personal electronics. By monitoring usage patterns, AI-powered algorithms can predict battery wear, adjust the charging process, and even send out alerts to users about potential problems before they arise. The proactive nature of AI in these use cases drastically improves battery health over time, ensuring longer usage periods and better performance without interruptions.

Environmental Considerations and Recycling

With hundreds of millions of personal devices and drones entering the market, there is a growing need for more battery recycling and environmentally friendly disposal. Innovations in battery recycling methods, like hydrometallurgy and direct recycling, aim to reclaim valuable materials from batteries, reducing the amount of raw materials that need to be extracted.

The Rise of Gigafactories

Manufacturing floor of a gigafactory, highlighting the potential for large-scale battery production | EMS

 

With the global demand for batteries continuing to surge, particularly in sectors like electric vehicles, grid storage, and consumer electronics, gigafactories are transforming the battery industry. These large-scale production facilities are essential for meeting the growing need for high-performance batteries, reducing production costs, and driving innovations that impact the future of energy storage.

A big topic we had at The Battery Show was how gigafactories are necessary for growing the battery industry and how we can make gigafactories even better- whether it’s using better materials in designing these gargantuan manufacturing powerhouses, finding renewable sources of energy to power them, or the best way scale production while decreasing costs.

 

Scaling Production for Lower Costs

With the global demand for batteries continuing to surge in sectors like electric vehicles, grid storage, and consumer electronics, gigafactories are necessary to meet production and manufacturing needs.

Gigafactories are the only manufacturing hubs with the capability and capacity to produce high-quantity goods at a much cheaper price.

Keeping the price point low is integral for growth, with more individuals, companies, and governments seeking out battery-powered goods and EVs.

Localized Production for Supply Chain Resilience

The reliance on long-distance supply chains is a problem with the growing battery industry.

By having local gigafactories, businesses can reduce transportation costs and minimize environmental impact.

Localizing gigafactories is especially important in protecting against geopolitical factors and global supply chain challenges.

Innovations in Battery Composition and Manufacturing

Gigafactories provide a centralized hub of innovation, pushing the technological boundaries in battery composition and manufacturing.

With gigafactories, we have committed professionals, businesses, and innovators working around the clock to find the pinnacle of battery design, product distribution, and energy storage systems.

AI for Predictive Maintenance and Quality Control

AI-fueled technologies are being used more and more to increase quality control, monitor equipment health, and optimize manufacturing schedules.

AI can detect errors, predict possible equipment failures, and optimize production schedules by analyzing real-time data from manufacturing processes.

This minimizes waste, improves efficiency, and ensures that each battery produced meets rigorous standards, ultimately driving down costs and improving the reliability of batteries produced at scale.

Environmental Impact and Sustainability Initiatives

A large concern with the growing number of gigafactories is the increase in their carbon footprint.

While batteries are touted as a green solution, the environmental impact of mining raw materials, producing battery materials, shipping goods, and creating a robust energy storage system can all add to pollution and waste.

Luckily, more green, environmentally friendly gigafactories are being made than ever before.

These factories use sustainable practices to reduce their carbon footprint, focusing on recycling, efficiency, and renewable resources.

These initiatives help address the environmental concerns associated with large-scale battery production and align with global sustainability goals.

 

The Battery Industry is primed to become one of the biggest markets in the world. As the demand for high-quality, innovative battery solutions rises, EMS will continue providing expert clad metals that can do more than any single metal, helping propel the battery industry forward with less expensive, high-conductive battery materials.

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