Altech Batteries Ltd (ASX:ATC, OTC:ALTHF) has lifted the capacity of its CERENERGY® sodium chloride solid-state battery packs to 90 kilowatt-hours (kWh) following research and development work on an expanded module design.
The advance comes from shifting to a 72-cell “beehive” arrangement within each module, up from the current 48-cell configuration. As a result, a five-module pack can now deliver 90 kWh of energy — a 50% increase on the previous 60-kWh output — while retaining the existing casing and factory setup. Crucially, the change requires no new infrastructure or production line modifications.
Diagram showing the packing of cells in same size module from 48 to 72 cells
Higher density, lower cost
According to Altech, the redesign delivers system-level advantages, including higher energy and power density, improved thermal behaviour, and cost reductions of about 30% at both the module and pack levels.
Thermal modelling confirmed uniform heat distribution across cells, reducing temperature variation, lowering internal resistance, and maintaining stable performance under load.
Thermal modelling conducted to assess temperature profile of expanded module
Engineering refinements — such as simplified cell contacting, optimised welding, repositioned temperature sensors, and a redesigned frame — are expected to improve assembly efficiency, structural strength and long-term reliability.
“Achieving a 72-cell beehive module design that lifts pack capacity to 90 kWh — without any change to the existing casing or factory setup — is a significant milestone,” said group managing director Iggy Tan.
“Not only does this innovation increase energy density, it also simplifies engineering, enhances thermal management, and reduces cost by nearly 30%,” he added. “These results strengthen the commercial competitiveness of CERENERGY® and confirm its scalability towards full industrial production.”
Strengthening competitiveness
The new design concept positions Altech to improve its euros-per-kilowatt-hour (€/kWh) metrics, a critical measure in the global battery market where competitiveness hinges on both performance and cost-efficiency.
While a final decision on the design has not yet been made, further modelling work is under way, alongside efforts to incorporate the expanded module into a grid-scale pack.
The company expects the refinements to accelerate its pathway towards commercialisation, supporting plans for a 120-megawatt-hour production facility in Saxony, Germany, through its joint venture with Fraunhofer IKTS.
Beyond lithium
Altech and Fraunhofer’s CERENERGY® technology is being advanced as a safer and more sustainable alternative to conventional lithium-ion batteries. The sodium chloride solid-state chemistry is fire- and explosion-proof, has a lifespan of more than 15 years, and can operate in extreme cold or desert climates.
Importantly, CERENERGY® batteries do not rely on lithium, cobalt, graphite or copper — materials subject to volatile pricing and supply chain risks. Instead, the technology uses readily available table salt, positioning it as a cost-stable solution for grid-scale energy storage.
The latest results build on recent milestones where prototype CERENERGY® modules demonstrated long cycle life and robust safety performance, reinforcing the project’s momentum toward industrial-scale production.
Read more: Altech’s CERENERGY® prototypes achieve long-life and safety milestones