How Far Away (Really) Are Solid State Batteries in EVs?

Higher up-front costs, range anxiety, limited model options, and scarce public charging infrastructure are all early barriers to buyers adopting electric vehicles (EVs). And although automotive engineers are continually enhancing EV efficiency by optimizing aerodynamics, reducing vehicle weight through lighter materials, improving electric motor design, and designing advanced thermal management systems, the inability to match an internal combustion engine (ICE) vehicle’s driving range and convenience has kept many Canadian buyers from making their next car a battery-electric one.

However, the promising advancements in next-generation technologies, such as solid-state batteries, could make driving an EV as convenient as driving a gas-powered vehicle.

The big question is when?

Why the Push for Solid-State Batteries?

Since the first electric cars arrived in the 1900s, extracting the most from available battery technology has always been a challenge. It started with rechargeable lead-acid batteries in the late 1850s, followed by the introduction of nickel-metal hydride (NiMH) batteries in modern EVs in the 1990s, then the arrival of lithium-ion batteries in the 2010s.

Compared to NiHM batteries, lithium-ion variants are cheaper to produce, more efficient, have higher energy density, and have a proven track record that no other technology has yet matched. Still, even the latest lithium-ion EVs can’t match gasoline-powered vehicles when it comes to driving range and the amount of time it takes to refill. The current limitations of lithium-ion battery energy density restrict the range to around 400 to 500 km, when most drivers want about 700 km or more, and the fastest EV chargers can still take over half an hour to charge from 10 to 80 per cent. This is where the potential gains in next-generation solid-state batteries are getting people in the business, as well as buyers, excited.

What Are the Benefits of Solid-State Batteries?

The list is long as to why the industry sees solid-state batteries as the next big step in the mass adoption of EVs. The combination of benefits over lithium-ion batteries includes:

More Driving Range: ‍Today’s lithium-ion batteries are limited by the weight of the liquid electrolyte and their graphite anodes. Instead, the “solid” in solid-state batteries refers to the use of a solid electrolyte instead of a flammable liquid, as well as high-capacity lithium metal anodes. This enables a higher energy density, providing a greater driving range within the same physical space. Solid-state batteries are also more stable in extreme climates, so driving range won’t be as negatively affected in the winter as it is with lithium-ion batteries, which can lose about 20 to 30 per cent of their range in cold weather.

Faster Charge Times: Charging an EV powered by a lithium-ion battery pack is hindered by the time it takes for the lithium ions to diffuse into the graphite anode. Solid-state batteries allow for faster ion transfer through the solid electrolyte. Less internal resistance means faster charging times.

Safer EVs: Solid-state batteries offer a significant safety advantage over lithium-ion batteries. The absence of a liquid electrolyte, which can lead to higher temperatures in lithium-ion batteries, makes solid-state batteries more thermally stable and less susceptible to catching fire.

Better Packaging: While high-mileage commuters benefit from the higher energy density of a solid-state battery, which delivers more range, another benefit is that they weigh less, which results in improved acceleration, braking, and handling. Solid-state batteries also give vehicle designers more freedom, as the absence of liquid and the ability to incorporate bipolar stacking allow for more compact and lighter battery designs.

Longer Battery Life: All batteries become less efficient over time. With lithium-ion batteries, their liquid electrolyte can create unwanted chemical side reactions and the formation of dendrites (this leads to a shorter lifespan). In contrast, solid-state batteries reduce these side reactions and dendrite growth, potentially leading to a longer battery life and less battery degradation.

Cheaper to Produce: Today, solid-state batteries are more expensive due to complex manufacturing processes and the high cost of solid electrolytes. But the potential for future cost reductions (like dry electrode printing, which uses less energy and eliminates toxic solvents; the use of abundant materials like sodium or sulphur, which can replace expensive lithium and cobalt; and the ability to eliminate the graphite anode) could simplify manufacturing and lower costs.

When Will the Solid-State Battery EVs Be Available for Sale?

Add up all these advantages, and the tangible gains over current lithium-ion batteries become obvious. According to Toyota, using a solid-state battery could increase an EV’s range by nearly 70 per cent and reduce DC fast-charging times by 10 to 80 per cent. For a current mainstream EV, such as the 2026 Toyota bZ, this would, in theory, result in a maximum driving range increase from around 460 to almost 780 kilometres. Instead of taking 30 minutes to charge its battery, it would take only three to 24 minutes.

When will consumers be able to purchase an EV with solid-state batteries? The quick answer is: hopefully soon.

Automakers and battery manufacturers are currently working to overcome the challenges related to production efficiency and cost before these batteries can be integrated into mass market production vehicles. (For reference, it took Toyota over a decade to accelerate lithium-ion battery development, starting in 2003, to finally debut in the fourth-generation 2016 Toyota Prius Prime plug-in hybrid electric vehicle.)[1] 

Toyota is targeting commercial production of solid-state battery EVs in the 2027-2028 timeframe. Hyundai is even more ambitious, with the aim of achieving this by the end of this year. Nissan has said it will be operating a pilot production line this year, with commercial production of EVs set to start in fiscal year 2028. Stellantis announced that it will begin testing its “semi-solid state” cells in a fleet of electric Dodge Chargers in 2026. No doubt, other EV makers will follow.

Despite these seemingly ambitious claims, given the current volatility of the car industry, including the geopolitical implications of tariffs and the challenges of sourcing rare earth materials for modern batteries, you still have time to save up for a solid-state battery-powered EV. The current consensus is that widespread availability of solid-state batteries in higher-volume vehicles is not expected until the 2030s.