New EV Batteries are Making Electric Cars Cheaper and Safer

If you bought an EV with a lithium iron phosphate (LFP) battery, you could expect lower car payments, less fire risk and more years of use out of your car — but you wouldn’t be able to go as far on a single charge as you could with the nickel manganese cobalt (NMC) batteries commonly found in American and European electric cars. That trade-off has made LFP batteries the go-to choice for standard-range EVs in China, helping to make electric cars more affordable and limit pollution. Now, American companies are starting to build their own LFP batteries to catch up to their Chinese rivals… But there are plenty of barriers for U.S. companies that want to adopt a technology dominated by Chinese firms. Tariffs and tax credit restrictions have made it too expensive for most American automakers to import LFP batteries from China, and national security concerns have made it hard for American companies to partner with Chinese battery makers to build factories in the United States…

Although American scientists invented LFP batteries in 1997, U.S. automakers didn’t invest in the technology. Instead, they bet on NMC batteries because they have longer range, a big concern for American EV buyers. “Everyone in the West thought LFP was a nonstarter five or six years ago,” said Adrian Yao, who founded STEER, a technology research group within Stanford University. “We really did have a myopic focus on” range, he added. That left the door open for Chinese companies to perfect LFP batteries, which have a few advantages. Instead of pricey nickel and cobalt, they use iron, which makes them 20 percent cheaper than NMC batteries, according to the International Energy Agency. While NMC batteries can be recharged up to about 1,000 times before they go kaput — which is enough to put 200,000 miles on most EVs — LFP batteries can last two or three times as long, according to Moura. Plus, LFP batteries’ chemistry makes them less likely to catch fire and easier to extinguish. An NMC battery, on the other hand, is so flammable that “you could put it underwater or in space, and it’ll keep burning because the oxygen it needs to keep the flame going is embedded within itself,” Moura said.

That safety advantage is key, because Chinese firms figured out they could pack LFP cells closer together inside a battery pack without risking a fire. That meant they could cram more energy into LFP batteries and nearly catch up to the range of NMC batteries. Last year, the Chinese battery giant CATL made the first LFP battery with more than 600 miles of range. Since LFP batteries are made from common materials and last longer, they also have a smaller environmental footprint than NMC batteries.
Ford used LFP batteries in its Mach-E sedan (2023) and F-150 Lightning pickup trucks (2024), according to the article, “while Rivian began using them in the basic trims of its R1S SUV and R1T pickup truck this year… American LFP factories are slated to open this year in St. Louis and next year in Arizona.”
And an environmental engineering professor at the University of California at Berkeley predicts LFP battery factories in the U.S. will “grow quite rapidly over the next five to 10 years.”