# SBIR Phase II: Metal Foils for High Energy Density, Low-cost, Lithium-ion Batteries

> **NSF 01002526DB NSF RESEARCH & RELATED ACTIVIT** · KHEMIA METALS INC (CA) · $1,230,631

## Abstract

The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase II project is the development of base-metal alloy foils as a cost-effective, lightweight replacement for copper current collectors in lithium-ion batteries (LIBs). Copper is currently the third most expensive and third heaviest component in LIBs, costing battery manufacturers over $7 billion annually. By replacing copper with these innovative foils, the project targets a long-term material cost reduction of over 50%, saving more than $3 per kilowatt-hour (kWh) and improving gravimetric energy density by over 5%. With LIB pack prices at approximately $107/kWh and batteries accounting for 40% of electric vehicle (EV) production costs, this innovation supports the national goal of reducing battery prices to $50–$75/kWh to achieve cost parity with internal combustion engine vehicles. Additionally, the project addresses critical supply chain vulnerabilities by offering a domestically produced alternative to copper foil, which is almost exclusively manufactured in Asia. By supporting domestic manufacturing, this project helps strengthen the U.S. battery supply chain, promote job creation, and reduce reliance on critical materials facing projected shortages, such as copper, while enabling global competitiveness for U.S.-based energy technology solutions.

The intellectual merit of this project lies in the novel development and application of base-metal alloys that are electrochemically stable aga

## Key facts

- **NSF award ID:** 2437742
- **Awardee organization:** KHEMIA METALS INC (CA)
- **SAM.gov UEI:** JNJQHFZ3GA79
- **PI:** Helen K Bergstrom
- **Primary program:** 01002526DB NSF RESEARCH & RELATED ACTIVIT
- **All programs:** Energy Storage or Transmission
- **Estimated total:** $1,230,631
- **Funds obligated:** $1,230,631
- **Transaction type:** Cooperative Agreement
- **Period:** 09/01/2025 → 08/31/2027

## Primary source

NSF Award Search: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2437742

## Citation

> US National Science Foundation, Award 2437742, SBIR Phase II: Metal Foils for High Energy Density, Low-cost, Lithium-ion Batteries. Retrieved via AI Analytics 2026-06-08 from https://api.ai-analytics.org/grant/nsf/2437742. Licensed CC0.

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