’THE HARDEST THING IN THE WORLD’
The biggest challenge battery innovators face is to design a reliable mass production process. Perfection is a tricky thing in the battery industry. Many mass-produced goods tolerate a reasonable flaw level. Batteries are very vulnerable: they either work or they do not. The challenge is to achieve manufacturing at scale with a highly consistent level of quality. A working prototype may promise the breakthroughs the world is waiting for. But the journey from the creation of a prototype to industrial manufacturing is a long one and many battery companies have failed along the way. At ION Storage Systems, Vice President of Research and Development, Dr. Elizabeth Santori, is in charge of developing the manufacturing process that will be critical for the success of the company. Below is an excerpt from an interview with Santori.
Jurriaan Kamp: Elon Musk has said that manufacturing batteries is “the hardest thing in the world”. Why?
Elizabeth Santori: “That is a bold claim from someone who sends rockets into space! Manufacturing any hardware is incredibly challenging, far more challenging than developing a new app or piece of software. Batteries require very high levels of precision for every individual component and for their assembly. And unlike a rocket, you have to manufacture millions/billions of them to be successful. The level of control, automation, and scale required is mind-blowing.”
Many new battery companies fail. What is ION doing right to become successful?
“The three things we are doing right is solving a problem that people care about, with a strong technology and a team that has the right culture and mindset to do it—open, passionate, knowledgeable, honest and creative. “
Will it be easier to mass produce solid-state batteries than the current lithium-ion ones?
“It will not be easier. I do not think it will be harder either. The upside will be in what the batteries can do: providing both a safe and high energy density. That battery does not exist today.”
What is the biggest challenge you need to overcome?
“There are two: pulling talent from all over the U.S. is critical. And then we are making a battery with a material that no one has put in a battery before.”
What is an example from a challenge industry/manufacturing in general was able to overcome that inspires you?
“I am inspired by seeing companies and products succeed that once were thought to be impossible to the point of foolishness. Tesla’s approach of using thousands of smaller and lighter cells to make a battery was incredibly disruptive. I remember it being mocked at the time. But ultimately it proved to be a genius engineering and company strategy. Gorilla glass being in every phone; mass production of silicon solar panels to meet aggressive financial and energy goals also come to mind.”
Is perfection possible?
“No, but it also is not necessary. The key thing is to design your system to tolerate and accommodate imperfections. That said: I am a scientist. Scientists are well known for seeking perfection. The engineers I work with would be pleased with my response.”
What do you do when you need to solve a problem?
“I first make sure I understand the problem, defining clearly what it is and understanding at a deep level why it exists. Do not react emotionally to what you think is happening. This first step is critical and is often overlooked in favor of jumping ahead to the fun, creative problem-solving phase: Then, I talk to smart, passionate, creative people. Once you know the problem you are trying to solve, bringing together the right people with different perspectives to brainstorm is the best—and most enjoyable—way to make a breakthrough. Finally, every solution has to fit in the business strategy. We are not an idea factory!”
