New 24M ETOP Battery Pack Technology Unleashes up to 50% More Electric Vehicle Range Through Unmatched Energy Density

Wednesday, September 03, 2025

September 3, 2025 — 24M Technologies, a pioneering technology company revolutionizing battery design and manufacturing, has developed a new battery packing system with unmatched energy density that can increase EV driving range by up to 50%. Called 24M ETOP™ (Electrode-to-Pack), the game-changing technology seals electrodes in thin polymer films that are then integrated directly into the pack to vastly improve packaging efficiencies. 

Currently, battery manufacturers and car makers build modules and packs from individual cells meaning that lithium-ion batteries feature a large proportion of inactive, non-energy-carrying materials — such as supporting metals and plastics — within a cell’s casing, adding cost and wasting space. 

24M ETOP replaces this approach by creating a sealed cathode/anode pair that eliminates the cell and module and unnecessary materials. This allows manufacturers to achieve the highest energy density for any chemistry (NMC, LFP, NCA, Sodium-ion, LTO, LiS, etc.) available at the pack level, because a higher percentage of the battery is electrodes, the energy-storing components. 

In fact, 24M ETOP makes it possible for electrodes to comprise 80% of a pack’s volume, compared to the 30% to 60% of traditional battery packs. Crucially, this innovation also gives car makers a new choice: offer customers improved EV ranges by packing more energy into a same-sized pack or reduce EV costs by using less expensive chemistries. 

For example, a 75kWh NMC (Nickel Manganese Cobalt) battery — the size and type used by many mid-sized electric vehicles — with 24M ETOP could be increased to over 100kWh using the same chemistry, increasing range by 33% all in the same sized pack. With 24M ETOP it becomes possible to swap NMC chemistry for less expensive LFP (lithium-iron phosphate) technology, resulting in a less costly pack, but with the same overall range. 

24M ETOP also offers unprecedented design flexibility that enables completely customisable battery packs in different voltages and virtually any shape. OEMs and designers can create shapes such as ovals and hexagons, or whatever is best to fit within the space available. This pack efficiency translates into higher performance and lower costs. 

There are major manufacturing benefits too. Because electrodes are sealed individually, electrode safety tolerances do not have to be as tight as in a traditional battery, improving yield and safety while reducing investment costs by eliminating the need for traditional high tolerance and precision equipment.

Because the sealed electrodes can be flipped, they can be connected in series and parallel arrangements, enabling anything from a compact, 48V battery, all the way up to a mixed series/parallel 400-800V pack, giving battery designers further freedom. 24M ETOP also enables cell formation to be done in series which can reduce formation equipment investment, one of the largest CAPEX items in today’s lithium-ion battery factories.

Naoki Ota, President and CEO at 24M Technologies said: "Minimizing packaging materials and wasted space, 24M ETOP brings a step change in performance, replacing traditional cell-to-module-to-pack construction with electrode-to-pack construction, maximizing energy density.  24M ETOP makes it easier to build compact, flexible and safe high voltage batteries, presenting a revolutionary opportunity for electric vehicle manufacturers – longer ranges with the same chemistry or the same range with lower cost, safer chemistries, both in the same space. It truly is the closest version of an ideal battery — it is essentially all active material in a sophisticated wrapper.” 

24M ETOP can also be used with 24M's Impervio separator, Eternalyte electrolyte, and its LiForever electrode, all of which are aimed at creating a fundamentally safer, higher performing and longer-lived battery through the reimagination of internal battery design. 

Fast Facts:

  • Latest game-changing innovation from 24M, a battery technology leader and innovator, maximises battery pack energy through a patented packaging system.

  • Called 24M ETOP (Electrode-to-Pack), the system replaces traditional cells by packing sealed electrodes, the components which carry energy, directly into the battery pack.

  • Sealed in thin polymer films and stacked on top of each other, 24M ETOP uses minimal materials to maximize energy density for any battery chemistry.

  • This innovation enables up to a 50% increase in electric vehicle (EV) range by packing more energy into a same space.

  • Safer and less expensive lower energy density chemistries can be used without sacrificing range or increasing the size of the battery pack.

  • 24M ETOP also offers unprecedented flexibility for designing bespoke battery packs of virtually any size, configuration, chemistry or voltage.

About 24M
24M answers the world’s need for affordable energy storage by offering revolutionary battery technologies and battery manufacturing platforms for EV, eVTOL, ESS, and consumer electronics solutions. By re-inventing today’s battery products and manufacturing methods, 24M solves critical, decades-old challenges associated with the world’s preferred energy storage products and technologies: reducing their high cost while improving their performance, safety and recyclability. Founded and led by some of the battery industry’s foremost inventors, scientists and entrepreneurs, 24M is headquartered in Cambridge, Mass. For more information, please visit www.24-m.com.

24M is a registered trademark of 24M Technologies Inc. Eternalyte, Impervio, 24M ETOP and LiForever are pending trademarks of 24M Technologies Inc.