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University of Michigan uses recycled Kevlar fiber to solve lithium-sulfur battery life cycle issues

(Credit: University of Michigan)

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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.”

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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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I’d love to hear from you! If you have any comments, concerns, or questions, please email me at joey@teslarati.com. You can also reach me on Twitter @KlenderJoey, or if you have news tips, you can email us at tips@teslarati.com.

Joey has been a journalist covering electric mobility at TESLARATI since August 2019. In his spare time, Joey is playing golf, watching MMA, or cheering on any of his favorite sports teams, including the Baltimore Ravens and Orioles, Miami Heat, Washington Capitals, and Penn State Nittany Lions. You can get in touch with joey at joey@teslarati.com. He is also on X @KlenderJoey. If you're looking for great Tesla accessories, check out shop.teslarati.com

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Tesla is sending its humanoid Optimus robot to the Boston Marathon

Tesla’s Optimus robot is heading to the Boston Marathon finish line

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Tesla’s Optimus humanoid robot will be stationed at the Tesla showroom at 888 Boylston Street in Boston, right along the final stretch of the Boston Marathon today, ready to cheer on runners and pose for photos with spectators.

According to a Tesla email shared by content creator Sawyer Merritt on X, Optimus will be at the Boston Boylston Street showroom on April 20, coinciding with Marathon Monday weekend. The Boston Marathon finishes on Boylston Street, and the surrounding area draws hundreds of thousands of spectators along with international broadcast coverage. Placing Optimus there puts it in front of a massive public audience at zero advertising cost.

The Tesla showroom is at 888 Boylston Street, between Gloucester Street and Fairfield Street. The final mile of the marathon runs directly along Boylston Street, with runners passing the big stores before reaching the finish line at Copley Square.

Optimus was first announced at Tesla’s AI Day event on August 19, 2021, when Elon Musk presented a vision for a general-purpose robot designed to take on dangerous, repetitive, and unwanted tasks. In March 2026, Optimus appeared at the Appliance and Electronics World Expo in Shanghai, where on-site staff stated that mass production of the robot could begin by the end of 2026. Before that, it showed up at the Tesla Hollywood Diner opening in July 2025 and at a Miami showroom event in December 2025.

Tesla’s well-calculated display of Optimus gives the public a low-pressure first encounter with a robot that Tesla is preparing  to soon deploy at scale. The company has previously indicated plans to manufacture Optimus robots at its Fremont facility at up to 1 million units annually, with an Optimus production line at Gigafactory Texas targeting 10 million units per year.

Tesla showcases Optimus humanoid robot at AWE 2026 in Shanghai

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Musk has said that Optimus “has the potential to be more significant than the vehicle business over time,” and separately that roughly 80 percent of Tesla’s future value will come from the robot program. Whether that holds depends on production execution. For now, Boston gets a preview of what that future looks like, standing at the finish line on Boylston Street while 32,000 runners pass by.

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Tesla expands Unsupervised Robotaxi service to two new cities

This expansion builds directly on Tesla’s existing operations. Robotaxi has been ramping unsupervised rides in Austin for months and maintains activity in the San Francisco Bay Area.

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Credit: Tesla

Tesla has taken a major step forward in its autonomous ride-hailing ambitions.

On April 18, the company’s official Robotaxi account announced that Robotaxi service is now rolling out in Dallas and Houston, Texas. The update signals the rapid scaling of unsupervised autonomous operations in the Lone Star State.

The announcement includes a compelling 14-second video captured from inside a Model Y. Shot from the passenger perspective, the footage shows the vehicle navigating suburban roads in both cities with zero driver intervention, with no Safety Monitor to be seen.

Tesla also shared geofence maps highlighting the initial service areas: a compact zone in Houston covering parts of Willowbrook and Jersey Village, and a similarly defined area in Dallas near Highland Park and central neighborhoods.

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This expansion builds directly on Tesla’s existing operations. Robotaxi has been ramping unsupervised rides in Austin for months and maintains activity in the San Francisco Bay Area.

With Dallas and Houston now live, Texas hosts three active hubs—an impressive concentration that triples the company’s Lone Star footprint in just weeks. The move aligns with Tesla’s Q4 2025 earnings guidance, which outlined a broader H1 2026 rollout across seven U.S. cities, including Phoenix, Miami, Orlando, Tampa, and Las Vegas.

Texas offers favorable regulations, high ride-share demand, and relatively straightforward suburban-to-urban driving patterns ideal for early autonomous scaling. While initial geofences appear modest—roughly 25 square miles per city—Tesla has historically expanded these zones quickly as it gathers real-world data.

Tesla confirms Robotaxi expansion plans with new cities and aggressive timeline

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Unsupervised operation marks a critical milestone: passengers can summon, ride, and exit without safety drivers, a leap beyond many competitors still requiring human oversight.

For Tesla, the implications are significant. Successful scaling in major metros could accelerate the transition to a fully driverless fleet, unlocking new revenue streams and validating years of Full Self-Driving investment.

Riders gain convenient, potentially lower-cost mobility, while the company edges closer to Elon Musk’s vision of Robotaxis transforming urban transport.

As Tesla pushes into more cities this year, today’s launch in Dallas and Houston underscores its momentum. Hopefully, Tesla will be able to expand unsupervised rides to another U.S. state soon, which will mark yet another chapter in this short-but-encouraging Robotaxi story.

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Tesla is pushing Robotaxi features to owner cars with Spring Update

Tesla has quietly begun rolling out one of its most forward-looking Robotaxi-inspired features to existing customer vehicles.

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Tesla is starting to push Robotaxi features to owner cars, and the first instances are coming as the Spring 2026 Update starts to roll out.

Tesla has quietly begun rolling out one of its most forward-looking Robotaxi-inspired features to existing customer vehicles.

With the 2026 Spring Update (version 2026.14+), the rear passenger display now features a fully interactive navigation map that works while the car is driving — a capability previously reserved for Tesla Robotaxi.

Until now, Tesla’s rear displays have been largely limited to media controls, climate settings, and static route overviews. The new interactive map transforms the backseat into an active navigation hub, exactly the kind of passenger-first interface Tesla has been prototyping for its driverless fleet.

In a Robotaxi, where no one sits behind the wheel, every rider will need intuitive, real-time map access. By shipping this UI into thousands of owner cars months ahead of the Cybercab’s planned unveiling, Tesla is stress-testing the software in real-world conditions and giving loyal customers an early taste of the autonomous future.

The rollout is still in its early wave. Only a small number of vehicles have received 2026.14.1 so far, but the feature is expected to expand rapidly in the coming weeks. Owners of Model S, Model X, Model 3, Model Y, and Cybertruck are all eligible.

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For buyers of the new Signature Edition Model S and X Plaid vehicles — whose deliveries begin in May — the update will likely arrive shortly after they take delivery, meaning the final chapter of Tesla’s flagship lineup will ship with cutting-edge Robotaxi preview tech baked in.

Elon Musk has long emphasized that Tesla ships supporting infrastructure well before new products launch. This rear-map rollout is a textbook example of that philosophy — quietly preparing both the software and the customer base for a world of fully driverless rides.

While the interactive map may seem like a modest convenience upgrade on the surface, its deeper purpose is unmistakable. Tesla is using its massive installed base of vehicles as a proving ground for the exact passenger experience that will define the Robotaxi era.

For current owners, it’s a free preview of tomorrow’s mobility; for the company, it’s invaluable data and real-world validation before the Cybercab hits the streets.

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