By ATN Editorial Team
Summary: 24M Technologies has launched its ETOP (Electrode-to-Pack) system, a breakthrough battery architecture that can extend EV range by up to 50% by eliminating traditional cells and modules. The technology seals electrodes in polymer films and integrates them directly into the pack, allowing electrodes to account for up to 80% of pack volume. This design boosts energy density, reduces cost, supports diverse chemistries, and enables flexible pack shapes for automakers.
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- Key engineering takeaway: ETOP maximises active material at the pack level by integrating electrodes directly into the battery pack, significantly improving volumetric efficiency.
- Why it matters: Automakers can extend range, lower costs, and design more versatile battery packs, making EVs more competitive against combustion vehicles.
24M Technologies, a pioneer in advanced battery design, has introduced 24M ETOP™ (Electrode-to-Pack), a new battery packing system that boosts energy density and can extend EV driving range by up to 50%. The technology seals electrodes in thin polymer films, which are then integrated directly into the pack, eliminating the need for conventional cells and modules that waste space and materials.
Traditional lithium-ion battery packs contain a high proportion of inactive components such as casings, supports, and plastics. By replacing these with sealed electrode pairs, 24M ETOP allows manufacturers to maximise the share of active material at the battery pack level, regardless of chemistry—NMC, LFP, NCA, sodium-ion, LTO, or LiS. With ETOP, electrodes can make up to 80% of the pack’s volume, compared to 30–60% in conventional designs.
This efficiency offers car makers flexibility: increase range by fitting more energy into the same-sized pack or reduce costs by switching to cheaper chemistries while maintaining range. For example, a 75kWh NMC battery can be scaled to over 100kWh in the same footprint, extending range by one-third. Alternatively, automakers can replace NMC with low-cost LFP while delivering similar performance.
Beyond battery density, ETOP introduces unmatched design freedom. Packs can be built in virtually any shape—oval, hexagonal, or fully customised—to fit available space, supporting both performance gains and cost reduction. Safety and yield also improve, since sealed electrodes require looser tolerances and less precision equipment, reducing capital investment.
Frequently Asked Questions
What is the 24M ETOP battery system?
24M ETOP (Electrode-to-Pack) is a battery architecture from 24M Technologies that eliminates conventional cells and modules by sealing electrode pairs in polymer films and integrating them directly into the battery pack. It can extend electric vehicle range by up to 50% compared with conventional pack designs and is chemistry-agnostic.
How does ETOP improve energy density over a conventional lithium-ion pack?
In a conventional lithium-ion EV pack, electrodes make up 30–60% of pack volume, with the remainder consumed by casings, supports and intra-pack plastics. ETOP allows electrodes to occupy up to 80% of pack volume by replacing cell and module structures with sealed polymer-film electrode pairs integrated directly into the pack — a step change in volumetric efficiency.
What chemistries can ETOP be used with?
ETOP is chemistry-agnostic. 24M Technologies states the system supports NMC, LFP, NCA, sodium-ion, LTO and lithium-sulphur electrodes. This lets automakers either maintain performance at lower cost — for example replacing NMC with LFP — or keep existing chemistry and increase range in the same pack footprint.
Can ETOP packs be built in non-rectangular shapes?
Yes. Because ETOP integrates sealed electrode pairs directly into the pack rather than packaging them inside rigid cell and module housings, the pack can be formed into oval, hexagonal or fully bespoke shapes to fit available body-in-white space. 24M Technologies also states that sealed electrodes tolerate looser manufacturing tolerances, reducing capital equipment precision requirements.
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