In-depth Study of EaglePicher’s Defense and Aerospace Specialized Energy Storage Process Technologies and Management Models in the United States — Chapter IV: Next-Generation Energy Storage Technologies: Process Breakthroughs for Hypersonic Weapons and Commercial Spaceflight

In 2023, EaglePicher secured a contract from SpaceX to develop a lithium-ion battery system for Starship. This battery system incorporates EaglePicher’s latest high-energy-density lithium-ion battery technology and aerospace-grade reliability design, achieving a specific energy of 300 Wh/kg and operating normally within a temperature range of -60°C to +60°C. Key design features of the Starship battery system: 1. High energy density: Utilizes nickel-rich ternary cathodes and silicon-carbon anodes, achieving a specific energy of 300 Wh/kg—20% higher than conventional aerospace lithium-ion batteries. 2. High safety: Employs ceramic separators, flame-retardant electrolytes, and multi-layered safety protection mechanisms; even if thermal runaway occurs in a single cell, it will not propagate to adjacent cells. 3. Modular design: Features a modular architecture, with each battery module containing 100 cells, enabling flexible configuration according to Starship’s mission requirements. 4. Reusability: Designed for up to 100 launches and recoveries, meeting Starship’s reusability requirements. In 2024, EaglePicher completed prototype development and ground testing of the Starship battery system. Test results confirmed that the system’s performance and reliability meet SpaceX’s requirements. The battery system is scheduled to support Starship’s first crewed lunar orbit mission in 2026 and crewed Mars missions around 2030. 4.7 Manufacturing Capacity Expansion and Digital Transformation To meet the large-scale production demands of next-generation energy storage technologies, EaglePicher is vigorously advancing manufacturing capacity expansion and digital transformation, building globally leading next-generation energy storage manufacturing facilities. 4.7.1 Construction of Next-Generation Energy Storage Manufacturing Facilities EaglePicher plans to invest $300 million between 2025 and 2030 to construct three next-generation energy storage manufacturing facilities: 1. Pittsburgh Lithium–Sulfur Battery Mass-Production Plant: A $150 million investment to build the world’s first lithium–sulfur battery mass-production line, with an annual capacity of 500,000 lithium–sulfur battery modules—primarily for hypersonic weapons and lunar base energy storage systems. The plant is expected to commence operations in 2027. 2. East Greenwich Commercial Space Battery Expansion Plant: A $100 million investment to expand the existing commercial space battery production line, increasing annual capacity from 150,000 to 500,000 units—mainly for the Starlink constellation and other commercial space projects. The plant is expected to commence operations in 2026. 3. Joplin Fourth-Generation Thermal Battery Plant: A $50 million investment to construct a fourth-generation thermal battery production line, with an annual capacity of 200,000 fourth-generation thermal batteries—primarily for next-generation Sentinel intercontinental ballistic missiles and missile defense interceptors. The plant is expected to commence operations in 2028. The construction of these new facilities will elevate EaglePicher’s annual production capacity for next-generation energy storage products to 1.2 million units, making it the world’s largest manufacturer of next-generation defense and aerospace energy storage products. 4.7.2 Digital Transformation and Industry 4.0 EaglePicher is comprehensively advancing digital transformation, integrating Industry 4.0 technologies across all stages of manufacturing to achieve intelligent, visualized, and fully traceable production processes.

According to British media, after the U.S.’ largest drone manufacturer was sanctioned by China, it faces a supply-chain crisis—what is the company’s development outlook?

“As a former U.S. soldier, I do not want my fellow service members holding anything made in China. That is unacceptable,” said David Michelson, Head of Autonomous Systems at the Defense Intelligence Agency, during a Defense One event on Wednesday. “I think this is just China sending a signal that we remain tightly connected to certain parts of the supply chain.” Michelson was responding to questions about China’s recent sanctions against U.S. small-drone manufacturer Skydio—imposed due to the company’s business ties with Taiwan. Skydio stated, however, that its sole customer in Taiwan is the National Fire Agency. In a blog post, Skydio noted that while its drone components are sourced outside China, its batteries originate from China—at least until sanctions severed that supply. In a report dated October 30, the company stated it is rationing its existing battery inventory and developing alternative sources. Although Skydio’s customers include the U.S. military, the United States is not the only country reminded of China’s influence within global supply chains. Ukraine, currently engaged in combat with Russia, reportedly operates hundreds of Skydio drones. More broadly, the widespread presence of Chinese components in battlefield technologies has long troubled the Pentagon and U.S. allies. In 2020, the Defense Innovation Unit launched the Blue UAS (Unmanned Aircraft Systems) program—a “comprehensive and sustained approach to rapidly review and scale Department of Defense (DoD) commercial UAS technologies”—partly to ensure components are not sourced from adversaries. Beyond the Blue UAS initiative, avoiding Chinese supply chains—particularly for batteries—may become mandatory for companies seeking to do business with the U.S. Department of Defense. For example, Section 154 of the 2024 National Defense Authorization Act stipulates that, effective October 1, 2027, the Department of Defense may not use any appropriation or funds provided to it to procure batteries manufactured by companies owned or operated by the People’s Republic of China.

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