Lyten Begins U.S. Production of Lithium-Metal Foil for Next-Gen Batteries

Company takes major step toward a fully domestic battery supply chain in response to geopolitical and supply chain pressures

Lyten Strengthens U.S. Battery Industry with Domestic Lithium-Metal Production

Lyten, a California-based supermaterial company, has announced the production of the first U.S.-made battery grade lithium-metal foil using domestic lithium alloys and raw materials. This achievement marks a major step in establishing a fully American battery supply chain—free from reliance on foreign-sourced critical minerals.

The announcement comes as U.S. government agencies and defense leaders emphasize the urgent need to reduce dependence on China for battery materials and manufacturing. Currently, most global battery supply chains depend heavily on Chinese processing of minerals like nickel, cobalt, and graphite.

Lyten’s Lithium-Sulfur batteries do not use any of these materials. Instead, they rely on a sulfur cathode and lithium-metal anode. This new manufacturing milestone allows Lyten to produce both cathodes and anodes entirely in the U.S., avoiding tariffs and supply chain vulnerabilities.

“To build a U.S. battery industry, we must solve the supply chain challenge,” said Dan Cook, Lyten Co-Founder and CEO. “We have already eliminated the need for nickel, manganese, cobalt, and graphite with our Lithium-Sulfur battery, allowing us to focus on local supply and production of lithium. Lyten will be the only battery manufacturer in the U.S. shielded from tariffs and critical minerals risk.”

A Tariff-Free, Fully Domestic Battery Supply Chain

Lyten’s approach supports a national push for secure, clean energy technologies. Unlike lithium-ion batteries, which often require overseas materials and processing, Lithium-Sulfur batteries can be made with widely available U.S. resources.

“Lithium is abundantly available across the United States, but the capacity to process lithium into battery grade materials is extremely limited in the U.S. Being able to design and process our own lithium-metal alloys and foils is a game changer,” said Celina Mikolajczak, Lyten’s Chief Battery Technology Officer. “It puts Lyten at the front edge of U.S. battery manufacturing.”

Lyten partnered with Creative Engineers, Inc. in New Freedom, Pennsylvania, to produce proprietary lithium alloys. The company sources lithium-metal feedstock from a facility in the Eastern U.S., then converts the material into lithium-metal foils at its San Jose facility. This foil is used directly in its Lithium-Sulfur battery production lines.

Support for Defense, Aerospace, and Electric Vehicles

Lyten’s batteries are now compliant with the National Defense Appropriations Act (NDAA), enabling secure applications in defense and aerospace. In addition to its San Jose plant, Lyten recently acquired Northvolt’s battery factory in San Leandro, California, to expand its U.S. production capacity.

In 2024, Lyten secured a $650 million letter of interest from the Export-Import Bank of the U.S. to scale up energy storage systems using Lithium-Sulfur technology. The company also announced collaborations to integrate its batteries into Chrysler’s Halcyon Concept EV, AEVEX Aerospace UAVs, and a demonstration mission aboard the International Space Station later in 2025.

An American Answer to Geopolitical Supply Chain Risks

Lyten’s expansion highlights how U.S. companies are stepping up to meet the challenge of geopolitical pressure and supply chain instability. By using materials like sulfur—which is abundant and often a byproduct of other industries—Lyten is building batteries that are both sustainable and secure.

Founded in 2015, Lyten has raised over $425 million and holds more than 510 patents. Its Lyten 3D Graphene platform is the foundation for advanced batteries, strong lightweight composites, and precision sensors.

Read more:

• Amprius Secures $15M UAV Battery Order: Scaling High-Performance Power for UAS
• Tulip Tech Opens US Offices Amid Growing Drone Battery Crisis
• DIU Issues New Solicitation for Drone Battery Technology
• Lyten Acquires Cuberg’s Facility to Boost US Lithium-Sulfur Battery Production for Drone and Defense Applications