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University of Michigan uses recycled Kevlar fiber to solve lithium-sulfur battery life cycle issues
The University of Michigan Chemical Sciences and Engineering team, led by Professor Nicholas Kotov, has developed a “new biologically inspired battery membrane” with recycled Kevlar fibers that could quintuple electric vehicle ranges and have a lifespan of 1,000 cycles.
The Ann Arbor, Michigan research facility is one of the best in the world, and Kotov, whose research focuses on the development of biomimetic nanocomposites, the self-assembly of nanoparticles, and chiral nanostructures, has worked to change the narrative on lithium-sulfur cells. “There are a number of reports claiming several hundred cycles for lithium-sulfur batteries, but it is achieved at the expense of other parameters—capacity, charging rate, resilience, and safety,” Kotov said in a press release from the University. “The challenge nowadays is to make a battery that increases the cycling rate from the former 10 cycles to hundreds of cycles and satisfies multiple other requirements including cost.”
Lithium-sulfur batteries can enable five times the capacity of standard lithium-ion cells, which are used in electric vehicles. However, as Professor Kotov mentioned in his quote, the lifespan is significantly decreased due to chemical reactions between molecules. The most common reason for reduced life cycles in lithium-sulfur batteries is dendrites, which are appendages that are designed to receive communications from other cells. These can pierce the membrane of cells, reducing the life span and thus the life cycle of a battery cell.
Another problem is polysulfides, or small molecules of lithium and sulfur, can form and flow to the lithium. They bond and cause blockages, reducing the effectiveness of the membrane. “The membrane is needed to allow lithium ions to flow from the lithium to the sulfur and back—and to block the lithium and sulfur particles, known as lithium polysulfides.”
However, Kevlar, the same material used in bulletproof vests, can stop dendrites from penetrating the membrane using dense aramid fibers found in the material. The cells that Kotov and his team developed use recycled Kevlar fibers. The Kevlar “can enable lithium-sulfur batteries to overcome their Achilles heel of cycle life,” caused by the two previously mentioned reactions between molecules.
An example of the Kevlar system is shown in the images below, as the typical Celgard membrane on the left allows lithium polysulfides to flow through. The Kevlar membrane (right) blocked the polysulfides from traveling through.
“Just half an hour on, the Celgard membrane (left) leaks lithium polysulfides. However, the U-M membrane (right) completely blocks the lithium polysulfides 96 hours later. Image credit: Ahmet Emre, Kotov Lab.” Credit: University of Michigan
“Achieving record levels for multiple parameters for multiple materials properties is what is needed now for car batteries,” Kotov stated. Kotov added that the design of the lithium-sulfur batteries is “nearly perfect” due to its capacity and efficiency reaching theoretical limits. It can also behave more resiliently than lithium-ion cells in warm and cold weather climates, which both have effects on range and efficiency. However, fast charging could reduce the number of lifespans, Kotov added.
Lithium-sulfur batteries could be a good alternative as sulfur is more readily available and abundant than cobalt, which is controversial due to its mining practices. However, automakers like Tesla are reducing cobalt in their batteries vying for other metals, like nickel, instead. Sulfur’s low lifespan and instability, as it changes in size by 78 percent during charging, reduced the possibility of automakers using it in the past, The Independent reported.
The research was funded by the National Science Foundation and the Department of Defense.
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Tesla to discuss expansion of Samsung AI6 production plans: report
Tesla has reportedly requested an additional 24,000 wafers per month, which would bring total production capacity to around 40,000 wafers if finalized.
Tesla is reportedly discussing an expansion of its next-generation AI chip supply deal with Samsung Electronics.
As per a report from Korean industry outlet The Elec, Tesla purchasing executives are reportedly scheduled to meet Samsung officials this week to negotiate additional production volume for the company’s upcoming AI6 chip.
Industry sources cited in the report stated that Tesla is pushing to increase the production volume of its AI6 chip, which will be manufactured using Samsung’s 2-nanometer process.
Tesla previously signed a long-term foundry agreement with Samsung covering AI6 production through December 31, 2033. The deal was reportedly valued at about 22.8 trillion won (roughly $16–17 billion).
Under the existing agreement, Tesla secured approximately 16,000 wafers per month from the facility. The company has reportedly requested an additional 24,000 wafers per month, which would bring total production capacity to around 40,000 wafers if finalized.
Tesla purchasing executives are expected to discuss detailed supply terms during their visit to Samsung this week.
The AI6 chip is expected to support several Tesla technologies. Industry sources stated that the chip could be used for the company’s Full Self-Driving system, the Optimus humanoid robot, and Tesla’s internal AI data centers.
The report also indicated that AI6 clusters could replace the role previously planned for Tesla’s Dojo AI supercomputer. Instead of a single system, multiple AI6 chips would be combined into server-level clusters.
Tesla’s semiconductor collaboration with Samsung dates back several years. Samsung participated in the design of Tesla’s HW3 (AI3) chip and manufactured it using a 14-nanometer process. The HW4 chip currently used in Tesla vehicles was also produced by Samsung using a 5-nanometer node.
Tesla previously planned to split production of its AI5 chip between Samsung and TSMC. However, the company reportedly chose Samsung as the primary partner for the newer AI6 chip.
Elon Musk
Elon Musk: Tesla could be first to build AGI in humanoid form
Musk’s statement was shared in a post on social media platform X.
Elon Musk predicted that Tesla could become one of the developers of Artificial General Intelligence (AGI) in humanoid form. Musk’s statement was shared in a post on social media platform X.
In his post, Musk stated that “Tesla will be one of the companies to make AGI and probably the first to make it in humanoid/atom-shaping form.”
The comment comes as Tesla expands development of its Optimus humanoid robot.
During Tesla’s Q4 earnings report, Elon Musk stated that production of the Model S and Model X would be phased out at its Fremont, California, facility. The vehicles’ production line will then be converted to a pilot line for Optimus. Tesla is looking to produce 1 million units of the humanoid robots annually to start.
Musk has previously stated that Optimus could eventually function as a von Neumann probe. The concept, proposed by mathematician John von Neumann, describes a machine capable of replicating itself using planetary resources and sending those replicas to other worlds.
Optimus would likely only be able to achieve this potential if it manages to achieve Artificial General Intelligence.
Other leaders in the AI sector have also expressed strong expectations about AGI’s potential. Demis Hassabis, CEO of Google DeepMind, recently spoke about the technology at the India AI Impact Summit 2026, as noted in a Benzinga report.
“It’s going to be something like ten times the impact of the Industrial Revolution, but happening at ten times the speed,” Hassabis said.
Elon Musk’s recent comments about Tesla producing a product with AGI could hint at further collaboration among his companies. So far, Tesla is actively pursuing autonomous driving, but it is xAI that is pursuing AGI with its Grok program.
Considering that Elon Musk mentioned a Tesla humanoid product with AGI, it appears that an Optimus robot running xAI’s AI models could become a reality.
xAI had recently merged with SpaceX, though reports suggest that Elon Musk is also considering an even bigger merger for all his companies, including Tesla.
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Tesla influencers argue company’s polarizing Full Self-Driving transfer decision
Tesla maintains it will honor transfers for orders with initial delivery windows before the deadline and offers full deposit refunds otherwise, citing longstanding fine print that the program is “subject to change at any time.”
Tesla’s decision to tighten its Full Self-Driving (FSD) transfer promotion has ignited fierce debate among owners and enthusiasts.
The company quietly updated its terms in late February 2026, changing the eligibility from “order by March 31, 2026” to “take delivery by March 31, 2026.”
What began as a flexible incentive to boost sales, allowing buyers to transfer their paid FSD (Supervised) to a new vehicle, now excludes many, particularly Cybertruck owners facing delivery delays into summer or later.
Tesla maintains it will honor transfers for orders with initial delivery windows before the deadline and offers full deposit refunds otherwise, citing longstanding fine print that the program is “subject to change at any time.”
The reversal has polarized the Tesla community, with accusations of a “bait-and-switch” clashing against defenses of corporate pragmatism. Many owners who placed orders under the original wording feel betrayed, especially as production backlogs and new unsupervised FSD rollout complicate timelines.
However, Tesla has allowed them to cancel their orders and receive a refund.
Critics of the decision argue that the change disadvantages loyal customers who helped fund FSD development, calling it poor communication and a revenue grab as Tesla pivots toward subscriptions.
Popular influencers have amplified the divide. Whole Mars Catalog struck a measured but firm tone, acknowledging the original “order by” language but emphasizing Tesla’s right to adjust terms. He has continued to defend Tesla in this particular issue:
Sad to see so many fans trashing Tesla with such extreme language.
LIARS!!! PATHETIC!!! And if you aren’t as furious and angry as they are they are you’re “worshipping” and saying “they can do no wrong”.
Let’s get real here. They’re not liars. They offered FSD transfer to us… https://t.co/3Ay7vGaVR6
— Whole Mars Catalog (@wholemars) March 3, 2026
He criticized extreme backlash as “dramatization” and “spoiled kids,” noting the unsupervised FSD era and broader sales challenges make blanket transfers financially risky. Whole Mars advocated for polite outreach to CEO Elon Musk over the issue.
Rather than “calling them out”, I would simply say “Hey Elon, really hoped to be able to do FSD transfer on my cybertruck but the terms changed. Would really appreciate if Tesla could extend this to everyone who ordered before the terms changes”
that would probably work
— Whole Mars Catalog (@wholemars) March 3, 2026
In a contrasting perspective, Dirty TesLA voiced sharper frustration, posting that blocking transfers feels “crazy” and distancing himself from “people that want to worship a corporation and say they can do no wrong.” His stance resonated with owners who view the policy flip as disrespectful to early adopters.
Popular Tesla influencer Sawyer Merritt captured the frustration felt by thousands. In a widely shared thread viewed over 700,000 times, Merritt detailed how pre-change Cybertruck orders now risk losing FSD eligibility unless their initial delivery window falls before March 31.
It’s not a contradiction, it’s a change in policy that Tesla just made an hour ago. I am trying to check if the change is retroactive to all existing orders, including Cybertruck AWD orders, because if it is, that sucks big time.
— Sawyer Merritt (@SawyerMerritt) February 28, 2026
The controversy underscores deeper tensions—between Tesla’s need for revenue discipline and owners’ expectations of goodwill. As FSD evolves toward unsupervised capability, the community remains split: some see the change as necessary business, others as a broken promise. Whether Tesla reconsiders under pressure or holds firm remains to be seen, but it does not appear they are planning to budge.
Tesla to discuss expansion of Samsung AI6 production plans: report
Elon Musk: Tesla could be first to build AGI in humanoid form
