Table of Contents
- Executive Summary: The Quasiliquid Electrolyte Revolution
- Market Size & Growth Projections (2025–2030)
- Key Drivers Accelerating Adoption in Battery Manufacturing
- Technology Deep-Dive: How Quasiliquid Electrolytes Work
- Competitive Landscape: Leading Manufacturers and Innovators
- Strategic Partnerships and Supply Chain Evolution
- Regulatory Environment and Industry Standards
- Application Spotlight: Electric Vehicles, Grid Storage, and Beyond
- Challenges & Barriers: Scale-Up, Stability, and Safety
- Future Outlook: Emerging Trends and Investment Opportunities
- Sources & References
Executive Summary: The Quasiliquid Electrolyte Revolution
Quasiliquid electrolytes are poised to transform lithium battery manufacturing, serving as a bridge between traditional liquid electrolytes and solid-state systems. In 2025, the industry is witnessing a surge in pilot-scale and early commercial-scale production of these advanced materials, driven by the need for higher safety, improved energy density, and operational stability in next-generation batteries.
Manufacturing quasiliquid electrolytes involves integrating polymeric or gel-forming materials with liquid solvents and lithium salts, often using precise mixing, casting, or infiltration techniques. This hybrid approach enables better ionic conductivity than most solid-state designs while retaining significant safety advantages over conventional liquid systems. Major battery manufacturers and chemical suppliers have accelerated investments and collaborations to optimize scalable production methods and supply chains.
In 2025, Samsung SDI continues to invest in the development and scaling of quasiliquid electrolyte production, aiming to deploy these materials in upcoming electric vehicle and energy storage products. Panasonic is similarly advancing pilot manufacturing lines, leveraging its expertise in both battery assembly and advanced materials processing. Meanwhile, LG Energy Solution has announced partnerships with specialty chemical providers to co-develop and industrialize quasiliquid formulations optimized for high-voltage, fast-charging applications.
Component supply remains a critical focus. Solvay and BASF are expanding their advanced electrolyte additive portfolios, with dedicated R&D lines for gel and polymer-in-salt matrices. These suppliers are investing in process innovation to ensure purity, consistency, and cost-effective volume scaling, which will be essential as automakers and device manufacturers demand larger quantities.
Outlook for the next several years is optimistic. The industry anticipates that by 2027, quasiliquid electrolytes will progress from pilot-scale to mainstream adoption in select premium EVs, high-performance consumer electronics, and grid-scale storage systems. The push for manufacturing innovation is expected to drive costs down, boost production yields, and further refine material compositions for specific end-use requirements. Continued collaboration between battery OEMs and chemical suppliers will be critical to overcoming technical and scaling barriers, setting the stage for broad commercialization of quasiliquid electrolyte batteries in the global market.
Market Size & Growth Projections (2025–2030)
The market for quasiliquid electrolyte manufacturing is poised for significant growth as the lithium-ion battery sector accelerates its transition toward next-generation chemistries. As of 2025, the commercialization of quasiliquid electrolytes—materials that blend the ionic conductivity of liquids with the stability of solids—remains at an early but rapidly evolving stage. Several major battery manufacturers and materials companies have announced investments and partnerships to develop scalable production methods for these electrolytes, aiming to address key challenges such as flammability, dendrite formation, and limited temperature stability in conventional liquid electrolytes.
Leading cell manufacturers are increasingly collaborating with materials suppliers to integrate quasiliquid electrolytes into high-energy-density and solid-state battery designs. For instance, Contemporary Amperex Technology Co., Limited (CATL) and Samsung SDI have both initiated pilot-scale lines for advanced electrolyte technologies, with a focus on hybrid and semi-solid systems that bridge the gap between current liquid and fully solid-state solutions. These pilot lines are expected to achieve multi-ton production capacities by 2026–2027, with further scale-up tied to the adoption timelines of next-generation electric vehicles and consumer electronics.
Materials producers such as 3M and Solvay are actively developing specialty polymers, ionic liquids, and gel matrices designed specifically for quasiliquid electrolytes. These companies report ongoing investments in expanding their specialty chemical production assets, aiming to meet anticipated demand from battery cell factories under construction in Asia, Europe, and North America. For example, Solvay has announced capacity expansions for specialty polymers used in advanced battery separators, which are compatible with emerging electrolyte formulations.
Looking ahead to 2030, capacity additions and process standardization are expected to drive down the cost of quasiliquid electrolyte manufacturing. Strategic partnerships between cell manufacturers and chemical companies are projected to accelerate technology transfer and streamline supply chains. By 2027–2028, industry observers anticipate that quasiliquid electrolytes could capture a meaningful share of new battery production lines, especially in high-performance automotive and grid storage markets. The ongoing evolution of regulatory frameworks—such as those emerging from the Global Battery Alliance—is also likely to support the adoption of safer, more sustainable electrolyte technologies.
Key Drivers Accelerating Adoption in Battery Manufacturing
Quasiliquid electrolytes are gaining significant traction in battery manufacturing as the industry seeks to balance safety, performance, and scalability. Several key drivers are accelerating their adoption in 2025 and are poised to shape the sector in the coming years.
- Enhanced Safety and Thermal Stability: Quasiliquid electrolytes offer improved thermal and electrochemical stability compared to conventional liquid electrolytes, a critical consideration for electric vehicles (EVs) and grid storage. These properties mitigate risks of leakage and combustion, addressing regulatory and consumer safety concerns. Panasonic Holdings Corporation and Samsung SDI have both intensified their research and development efforts into advanced electrolyte systems to deliver safer battery solutions.
- Compatibility with High-Energy Chemistries: The growing shift to high-nickel NMC and lithium-metal anodes in pursuit of greater energy density necessitates innovative electrolytes. Quasiliquid formulations enable these chemistries by providing stable interfaces and suppressing dendrite growth, unlocking higher capacity and longer cycle life. Contemporary Amperex Technology Co. Limited (CATL) is actively exploring such electrolytes for their next-generation cells, aiming for commercial-scale deployment.
- Manufacturing Process Advantages: Unlike fully solid-state electrolytes, quasiliquid systems can often be integrated into existing battery production lines with minimal modification, reducing capital expenditures and accelerating time-to-market. This is particularly attractive to established manufacturers seeking incremental improvements without full retooling. LG Energy Solution has highlighted the manufacturability benefits of hybrid and gel-based electrolytes in its public technical disclosures.
- Industry Collaboration and Standardization Efforts: Cross-industry collaborations are fostering shared standards and scalable manufacturing practices. Organizations such as Batteries Europe and alliances involving automakers and material suppliers are driving pilot projects and investment in pilot-scale manufacturing lines for advanced electrolytes.
- Regulatory and Market Pull: Stricter safety regulations and sustainability mandates in regions like the EU, the U.S., and China are pushing OEMs and suppliers to accelerate adoption of next-generation electrolyte solutions. The push for battery passports and carbon footprint transparency further incentivizes adoption of low-risk, high-performance materials.
With major manufacturers and industry bodies ramping up investment, and regulatory momentum favoring safer, more efficient batteries, the adoption of quasiliquid electrolyte manufacturing is expected to accelerate through 2025 and beyond, supporting the mass deployment of advanced lithium-ion and emerging battery technologies.
Technology Deep-Dive: How Quasiliquid Electrolytes Work
Quasiliquid electrolytes, often described as “gel-like” or “soft-solid” materials, represent a pivotal innovation in the next generation of rechargeable batteries. Their unique properties—combining the ionic conductivity of liquids with the mechanical stability of solids—are driving significant investment and rapid progress in manufacturing techniques. As of 2025, the production of quasiliquid electrolytes is transitioning from laboratory-scale synthesis to pre-commercial and pilot-scale manufacturing, spurred by advances in materials science and a growing demand for safer, higher-performance batteries.
The foundational process for manufacturing quasiliquid electrolytes typically involves dissolving lithium salts in a solvent matrix, which is then blended with polymeric or oligomeric binders to achieve the desired rheological properties. This hybrid composition is engineered to allow for facile ion transport while suppressing dendrite growth, a common problem in pure liquid electrolytes. Leading players such as Samsung SDI and LG Energy Solution are investing in proprietary mixing and casting methods, targeting precise control over viscosity and phase separation to optimize performance in lithium-metal and lithium-ion cells.
Recent years have seen the scaling of roll-to-roll coating and slot-die extrusion techniques, enabling the uniform deposition of quasiliquid electrolytes onto electrode substrates. Companies like Toray Industries are applying their expertise in advanced polymer processing to refine these techniques, ensuring high throughput and consistency suitable for automotive and grid-scale battery applications. In parallel, Mitsubishi Chemical Group is developing novel copolymer blends and cross-linking agents that enhance both ionic conductivity and mechanical robustness, facilitating compatibility with existing cell assembly lines.
Material purity and moisture control are critical in quasiliquid electrolyte production, as trace water can lead to undesirable side reactions. To address these challenges, Umicore and other materials suppliers are implementing advanced vacuum drying and inline monitoring systems, increasing yield and ensuring product consistency at scale.
Looking ahead to the next few years, the outlook for quasiliquid electrolyte manufacturing is one of accelerated commercialization. Multiple battery manufacturers have announced the integration of quasiliquid systems into prototype battery packs, with pilot lines expected to ramp up in 2025–2027. Industry roadmaps indicate a strong focus on supply chain localization and sustainability, including the use of bio-based polymers and recyclable solvents. As the technology matures, partnerships between chemical producers, battery manufacturers, and automotive OEMs are anticipated to drive further optimization in process efficiency and product performance, heralding a new era in energy storage safety and capability.
Competitive Landscape: Leading Manufacturers and Innovators
The competitive landscape for quasiliquid electrolyte manufacturing is rapidly evolving as demand for safer and higher-performing batteries intensifies. In 2025, established battery manufacturers, chemical companies, and emerging startups are investing heavily in scaling up production, refining formulations, and securing intellectual property in this promising subsector.
Among global leaders, LG Chem has publicly committed to advancing next-generation battery materials, including quasiliquid electrolytes, to improve lithium-ion battery safety and energy density. The company’s R&D focus has shifted toward semi-solid and quasiliquid systems that can be integrated into their existing Gigafactory-scale production lines, with pilot-scale demonstrations reported in 2024 and commercial rollouts anticipated by 2026.
Toray Industries, a major Japanese chemical manufacturer, has also accelerated its development of advanced electrolytes, leveraging its polymer chemistry expertise. Their 2025 roadmap includes partnerships with automotive and stationary storage battery producers to co-develop scalable processes for quasiliquid electrolyte integration, aiming to deliver enhanced thermal stability and longer cycle life.
Chinese battery giant Contemporary Amperex Technology Co. Limited (CATL) remains at the forefront, investing in both proprietary electrolyte formulations and supply chain resilience. CATL has announced collaborative agreements with specialty materials companies to secure precursors and co-develop manufacturing techniques, with pilot production lines for quasiliquid electrolytes set to reach multi-ton scale in 2025.
In the United States, 3M has expanded its advanced materials division to include pilot facilities for novel electrolyte systems, targeting electric vehicle and grid applications. The company’s approach emphasizes scalable, environmentally friendly production methods and compatibility with existing cell assembly infrastructure.
Startups are also shaping the landscape, driving innovation and partnerships with established players. For example, Sion Power is advancing hybrid electrolyte technologies to support high-capacity lithium-metal batteries, with demonstration-scale manufacturing underway and commercial partnerships in negotiation as of early 2025.
Looking ahead, the sector is expected to witness increased joint ventures and technology licensing as manufacturers race to achieve cost-effective, large-scale production. Strategic collaborations between materials suppliers, cell producers, and automotive OEMs will be central to overcoming technical and supply chain challenges. Regulatory scrutiny over safety and sustainability will further shape competition, favoring manufacturers who can deliver robust, scalable, and compliant quasiliquid electrolyte solutions.
Strategic Partnerships and Supply Chain Evolution
The manufacturing landscape for quasiliquid electrolytes is undergoing a significant transformation in 2025, driven by strategic partnerships and the evolution of global supply chains. As the battery industry accelerates its transition toward next-generation chemistries, quasiliquid electrolytes—offering a balance between safety and high ionic conductivity—are emerging as a focal point for innovation and collaboration.
In 2025, several leading battery producers and materials suppliers are formalizing joint ventures and technical alliances to secure the scale-up of quasiliquid electrolyte production. Contemporary Amperex Technology Co., Limited (CATL), for example, has expanded its collaboration with specialty chemical companies to develop proprietary formulations, aiming to integrate these electrolytes into commercial solid-state and semi-solid battery platforms. Such partnerships are not only accelerating research and pilot-scale synthesis but also establishing robust supply agreements for critical raw materials such as lithium salts, solvents, and polymer matrices.
Similarly, Toray Industries, Inc. has intensified its cooperation with battery OEMs and upstream chemical suppliers to enhance the scalability and consistency of quasiliquid electrolyte manufacturing. Their focus includes the co-development of advanced separator materials compatible with new electrolyte systems, optimizing both performance and manufacturability at gigafactory scales. These efforts are being consolidated through updated memoranda of understanding (MoUs) and multi-year procurement contracts that provide stability in an otherwise volatile raw materials market.
Supply chain evolution is also marked by new investments in regional manufacturing hubs. BASF has announced the establishment of dedicated production lines for battery-grade solvents and additives tailored for quasiliquid applications at its European sites, aiming to localize supply and reduce logistical risks. Meanwhile, Umicore is collaborating with electrolyte start-ups to integrate advanced purification and recycling processes for electrolyte precursors, enhancing both supply security and sustainability.
Looking ahead, the outlook for quasiliquid electrolyte manufacturing in the next few years is shaped by the increasing complexity of value chain integration. The ecosystem is expected to see more multi-lateral partnerships, with battery cell makers, automotive OEMs, and chemical giants co-investing in large-scale pilot plants and shared intellectual property pools. This trend is anticipated to drive down costs, accelerate regulatory compliance, and support the commercialization of safer, high-performance batteries for electric vehicles and stationary storage.
As regulatory frameworks evolve and demand for energy-dense, non-flammable batteries grows, the strategic alignment of supply chains and partnerships will be crucial in moving quasiliquid electrolyte technology from pilot to mainstream deployment.
Regulatory Environment and Industry Standards
The regulatory landscape for quasiliquid electrolyte manufacturing is evolving rapidly as the battery industry seeks to balance innovation, performance, and safety. In 2025, regulatory authorities and standards organizations are focusing on establishing robust frameworks to address the unique properties of quasiliquid electrolytes—materials that bridge the gap between conventional liquid and solid-state electrolytes, offering enhanced safety and ionic conductivity for next-generation lithium batteries.
Key developments include the revision and expansion of international standards by bodies such as the International Organization for Standardization (ISO) and the International Electrotechnical Commission (IEC), which are updating protocols to include new classes of electrolytes. These revisions emphasize chemical stability, thermal runaway prevention, and recycling compatibility. For instance, ISO/TC 22/SC 37 and IEC TC 21 have both initiated working groups to define test methodologies specific to hybrid and quasiliquid materials.
In the European Union, the European Chemicals Agency (ECHA) is updating its REACH (Registration, Evaluation, Authorisation, and Restriction of Chemicals) registration requirements to include substances commonly used in quasiliquid electrolytes, such as polymer gel matrices and non-volatile plasticizers. This will require manufacturers to provide detailed toxicological and environmental impact data before market entry. Similarly, the proposed EU Battery Regulation, slated for implementation by 2026, will require battery manufacturers to trace and report the chemical composition of electrolytes, including those with quasiliquid characteristics, throughout the supply chain.
In the United States, the Environmental Protection Agency (EPA) is actively reviewing new electrolyte chemistries under the Toxic Substances Control Act (TSCA), while the UL Solutions is updating its UL 2580 and UL 1973 standards for battery safety to reflect new risks and performance profiles unique to quasiliquid formulations. These updates include stricter fire resistance and off-gassing tests for battery packs using hybrid electrolyte systems.
Industry groups such as the Battery Council International (BCI) and the Batteries Europe are collaborating with manufacturers to develop best practices and harmonize testing procedures. Major manufacturers, including LG Energy Solution and Contemporary Amperex Technology Co. Limited (CATL), have already begun participating in pilot compliance programs and are sharing anonymized safety and performance data to facilitate the development of global standards.
Looking ahead, the next few years are expected to see increased regulatory clarity and harmonization, particularly as commercialization of quasiliquid electrolytes accelerates. Manufacturers investing in compliance and transparent reporting are likely to secure early market access, while laggards may face delays due to evolving safety and environmental requirements.
Application Spotlight: Electric Vehicles, Grid Storage, and Beyond
Quasiliquid electrolytes have emerged as a promising solution for next-generation lithium-ion and lithium-metal batteries, offering a unique compromise between the high ionic conductivity of liquid electrolytes and the enhanced safety of solid-state systems. As demand accelerates for electric vehicles (EVs) and stationary grid storage, the manufacturing landscape for quasiliquid electrolytes is evolving rapidly through 2025 and into the next few years.
Several major battery manufacturers and materials suppliers are scaling up production processes to meet the performance and safety requirements set by automotive and energy storage OEMs. LG Chem and Samsung SDI have both disclosed ongoing investments in advanced electrolyte production lines, targeting improved cycle life and thermal stability for EV applications. Their efforts focus on integrating polymer-based gel electrolytes and ionic liquid-infused systems, which are the foundation of many quasiliquid formulations.
In 2025, Toray Industries continues to supply high-purity polymer matrices used as hosts for liquid electrolytes, enabling scalable roll-to-roll processing compatible with large-format lithium battery manufacturing. Similarly, Solvay is expanding its portfolio of specialty salts and solvents optimized for quasiliquid chemistries, addressing both performance and regulatory requirements for automotive-grade battery packs.
The push for rapid manufacturing scalability is also evident in China, where Contemporary Amperex Technology Co. Limited (CATL) has revealed pilot lines for advanced electrolyte integration, supporting their roadmap for high-energy density EV batteries and grid storage modules. These pilot lines utilize automated mixing and encapsulation to ensure quality and consistency at industrial scale.
Looking ahead, industry collaborations are expected to accelerate the adoption of quasiliquid electrolytes. Robert Bosch GmbH is working with cell manufacturers to co-develop optimized electrode-electrolyte interfaces, a critical step for mass-market deployment. Meanwhile, regulatory bodies are updating guidelines to facilitate the safe introduction of new electrolyte materials into the EV and grid markets.
The outlook for 2025 and beyond suggests that quasiliquid electrolyte manufacturing will be characterized by increased automation, vertically integrated supply chains, and a focus on scalable, environmentally conscious processes. As pilot and commercial-scale production lines are commissioned by leading suppliers, the sector is poised for significant growth, supporting the widespread electrification of transport and resilient grid infrastructure.
Challenges & Barriers: Scale-Up, Stability, and Safety
Quasiliquid electrolyte (QLE) manufacturing faces several formidable challenges as the technology moves from laboratory-scale innovation to industrial production, particularly in the context of 2025 and the immediate years ahead. The most pressing barriers are associated with large-scale process engineering, long-term stability, and ensuring stringent safety standards.
Scale-Up Challenges
Transitioning from gram-scale synthesis to kilogram- and ton-scale manufacturing presents difficulties unique to QLEs due to their hybrid phase nature. Processes such as precise mixing, solvent exchange, and polymer network formation require tight control over temperature, humidity, and contamination. Batch-to-batch consistency remains a significant concern, as small variations in precursor purity or process parameters can result in substantial performance deviations. Despite advances in pilot-scale facilities, few companies have demonstrated fully continuous processes for QLEs. For instance, LG Chem and Toray Industries are actively exploring scalable synthesis routes, but both note that current pilot lines struggle with throughput and yield optimization for QLEs compared to conventional liquid electrolytes.
Stability Limitations
A core challenge lies in achieving the required electrochemical and mechanical stability for commercial battery applications. QLEs must maintain low ionic resistance and high interfacial compatibility with electrode materials over thousands of cycles and a wide temperature range. Moisture uptake and phase separation remain persistent risks during storage and cell assembly, especially when manufacturing environments are not rigorously controlled. Companies such as Panasonic Corporation have highlighted the need for advanced drying and sealing protocols, as even trace water can degrade QLE performance. Furthermore, real-world testing by Toshiba Corporation indicates that stability under rapid charge/discharge conditions still lags behind that of established liquid electrolyte systems.
Safety and Regulatory Barriers
Safety is paramount, particularly because QLEs are often proposed as safer alternatives to flammable organic solvents. However, the inclusion of certain plasticizers or lithium salts can introduce new hazards. Regulatory approval is also a bottleneck, with requirements for toxicology, fire resistance, and end-of-life disposal still evolving. Robert Bosch GmbH has reported ongoing dialogue with European regulatory bodies to define QLE-specific safety protocols, especially for automotive applications. The absence of harmonized international standards further complicates cross-border commercialization.
Outlook
Progress is expected as leading manufacturers invest in process automation, advanced materials handling, and environmental controls. However, significant barriers remain for widespread adoption of QLEs in large-format batteries by 2025–2027. Collaborative standard-setting efforts and public–private partnerships are likely to accelerate solutions, but the sector will require persistent R&D to resolve the core issues of scalable, stable, and safe QLE manufacturing.
Future Outlook: Emerging Trends and Investment Opportunities
Quasiliquid electrolytes—hybrid materials that combine the high ionic conductivity of liquid electrolytes with the improved thermal and mechanical stability of solids—are gaining significant momentum in the battery manufacturing landscape as the industry seeks safer, higher-performance alternatives to conventional liquid electrolytes. The period from 2025 onwards is set to mark pivotal developments in both the scaling and innovation of quasiliquid electrolyte manufacturing.
Leading battery manufacturers and material suppliers are actively investing in pilot and pre-commercial scale production lines for advanced electrolytes. Samsung SDI has announced efforts to commercialize quasi-solid (quasiliquid) electrolytes, aiming to introduce these materials into next-generation lithium-ion and solid-state batteries by the latter half of the 2020s. Their manufacturing roadmap includes refining solvent-salt-polymer ratios and optimizing scalable mixing and casting processes.
Similarly, Toray Industries has developed polymer-based quasiliquid electrolytes that are entering pilot-scale production in 2025, targeting applications in electric vehicles (EVs) and grid storage. The company is investing in roll-to-roll coating and advanced drying systems to ensure uniform electrolyte distribution and minimize impurities, which are critical for industrial adoption.
In China, Contemporary Amperex Technology Co., Limited (CATL) is scaling up its R&D and manufacturing of hybrid electrolytes, including quasiliquid variants. CATL is collaborating with upstream chemical suppliers to secure high-purity precursors and is exploring modular manufacturing lines that can flexibly switch between liquid, solid, and hybrid electrolyte production depending on market demand.
From a technology outlook, 2025–2027 is expected to see breakthroughs in electrolyte formulation—such as the incorporation of novel lithium salts, functional additives, and nanostructured polymers—to further boost safety and cycling stability. Manufacturing trends will likely emphasize automation, real-time monitoring, and closed-loop quality control to meet the stringent purity and consistency requirements of automotive OEMs and consumer electronics manufacturers.
Investment opportunities are emerging across the supply chain, from specialty chemical suppliers scaling up production of tailored solvents and salts, to equipment manufacturers providing precision mixing, filtering, and coating systems. Strategic partnerships and joint ventures are anticipated as companies seek to secure intellectual property and first-mover advantages in the quasiliquid electrolyte space.
Overall, the next few years will be characterized by rapid scaling of pilot lines, closer integration with battery cell assembly processes, and growing commercial validation—paving the way for broader adoption of quasiliquid electrolytes in high-performance lithium-ion and solid-state batteries.
Sources & References
- BASF
- Contemporary Amperex Technology Co., Limited (CATL)
- Mitsubishi Chemical Group
- Umicore
- Sion Power
- International Organization for Standardization (ISO)
- European Chemicals Agency (ECHA)
- UL Solutions
- Battery Council International (BCI)
- Robert Bosch GmbH
- Toshiba Corporation