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Tesla battery researchers open path to all-electric range extender concept
Tesla has solidified itself as an industry leader when it comes to electric vehicles and their range. However, an EV’s range could always be improved, and the company has taken great efforts to make this possible. One of these was outlined by Tesla’s battery researchers, who recently published the results of a test that cycles lithium metal on graphite to form hybrid lithium-ion/lithium metal cells. This particular innovation could open the door to an all-electric range extender.
Other automakers have used range extenders in the past, but they’ve been comprised of small petrol-powered engines that are used as a generator to recharge the vehicle’s battery pack when it is low on range. The process of cycling lithium metal on graphite, on the other hand, could lead to a 20% higher energy density than the traditional lithium-ion cells that power the Tesla’s vehicles.
Tesla’s battery research team, led by Jeff Dahn of Dalhousie University, has found a way to create a range extender of sorts without having to keep a small gas engine in the vehicle. Tesla detailed its findings in a research paper that was published to ScienceDirect on April 30. Titled “Cycling Lithium Metal on Graphite to Form Hybrid Lithium-Ion/Lithium Metal Cells,” Dahn and his researchers outlined the testing process.
The findings proved a possible 20% increase in range when using the range extender, which is comprised of “hybrid cells” that use Lithium-Ion and Lithium Metal. The cells also used an optimized electrolyte, and pressure enabled reversible plating on graphite.
The paper states:
“A hybrid anode cell design is proposed involving lithium metal plating on top of graphite that provides a 20% increase in energy density over conventional lithium-ion cells. Pouch cells with hybrid graphite-lithium metal anodes cycled with conventional electrolytes fell below 80% capacity in under 15 cycles. However, with a dual-salt electrolyte and applied mechanical pressure optimized for lithium metal cycling, hybrid cells achieved over 150 full (100% utilization) cycles before falling below 80% capacity with a CE of 99.6% for lithium metal plating on graphite.
“We also found that intermittent high energy (100% utilization) cycles utilizing lithium metal can be dispersed among hundreds of conventional lithium-ion cycles where only the graphite is utilized. Operating the cell with this intermittent protocol shows minimal impact to the underlying graphite capacity. Therefore, these hybrid cells can operate well in “lithium-ion mode” with periodic high energy full cycles accessing the lithium metal capacity.”
Tesla’s new findings show that increased energy density is made possible with the hybrid concept. When combining lithium-ion cells with lithium metal, energy density improves as the graphite anode utilized in traditional lithium-ion cells is not capable of handling the increased energy. The utilization of a dual-salt electrolyte also increases density and decreases battery cell degradation.
Tesla’s battery researchers described the advantages of the hybrid lithium-ion/lithium metal cells in the discussion below.
“If an electric vehicle with a conventional lithium-ion battery can deliver a range of 400 km, then hybrid cells could enable a range of 480 km. By capping the upper cut-off voltage of hybrid cells to operate in lithium-ion mode, the average cell voltage and delivered capacity will decrease. As a result, operating a hybrid cell in lithium-ion mode delivers an energy density of 530Wh/L, about 25% less than a conventional lithium-ion cell.
“This would result in a range of 300 km. In a study of driving behavior for EVs, Smart et al.34 showed that only 1% of daily trips are longer than 325 km on average. Therefore, operating hybrid cells most of the time in lithium-ion mode enabling a range of 300 km, while periodically using the lithium metal portion for long > 400 km trips, as mimicked by this testing protocol, should be viable for most drivers.”
It should be noted that the Tesla battery researchers’ study is only in their initial stages. Thus, it may take some time before the technology gets rolled out to Tesla’s fleet. The wait would likely be worth it though, as the hybrid cells could open the door to all-electric vehicles with range extender features. This would be incredibly useful for electric vehicle owners who take long road trips with family, and it could also be a notable step towards EVs gaining range parity with their petrol-powered counterparts.
In a major development that will inevitably strengthen Tesla’s dominant position in the American EV market, Polestar has been effectively banned from selling new vehicles in the United States, starting with the 2027 model year.
The U.S. Department of Commerce denied Polestar authorization under the Connected Vehicle Rule, which prohibits vehicles containing certain connected technologies (Cellular, Wi-Fi, Bluetooth, etc.) linked to China or Russia due to national security risks, including potential data collection on American drivers.
🚨 A Tesla competitor goes down
Polestar will no longer sell new vehicles in the United States starting with the 2027 model year.
The U.S. Department of Commerce denied the brand authorization under the Connected Vehicle Rule, which restricts the sale of cars with software and… pic.twitter.com/TrwnQeoiES
— TESLARATI (@Teslarati) June 25, 2026
Polestar, which is majority-owned by China’s Geely Holding, could not obtain the required exemption despite producing some models domestically.
Polestar confirmed it will sell off any remaining inventory of the Polestar 3 and Polestar 4 models, while continuing service and warranty support for existing customers. No new models or major refreshes will reach U.S. buyers, and the company is pivoting its growth strategy to Europe, where it already generates the vast majority of its sales.
The outcome removes a direct premium EV competitor that had positioned itself as a stylish, performance-oriented alternative to Tesla’s lineup. The Polestar 2 challenged the Model 3, while the Polestar 3 and 4 targeted segments overlapping with the Model Y and upcoming Tesla offerings. Polestar’s U.S. sales had already been sluggish amid intense competition and slower demand, representing just 6 percent of its global volume in the first quarter of 2026.
While Polestar was not on Tesla’s level in the U.S., it still places a dent in the evergrowing field of Tesla competitors in the country, where it has long dominated EV sales.
Tesla faces none of these hurdles. As a U.S.-founded and U.S.-headquartered company with major manufacturing in Fremont, Austin, and Nevada, Tesla’s vehicles are built with compliant domestic and allied supply chains. Its Full Self-Driving technology, over-the-air software updates, and vertically integrated ecosystem were developed entirely in-house without foreign ownership entanglements that trigger national security reviews, at least in the U.S.
Of course, it did face a similar threat in China a few years back:
Elon Musk responds to reports of Tesla ban among China’s military over security concerns
The Connected Vehicle Rule, first advanced under the prior administration and upheld under the current one, is part of a broader U.S. effort to protect the domestic auto industry and critical technology from Chinese influence. High tariffs on Chinese-made EVs and related restrictions have already reshaped the market. Tesla benefits directly: it avoids these barriers while continuing to lead in U.S. EV sales volume, Supercharger network expansion, and energy storage integration.
By clearing Polestar from the new-vehicle playing field, the policy reduces competitive pressure in the premium and performance EV segments where Tesla has invested billions. American consumers seeking cutting-edge electric vehicles now have one fewer option tied to foreign adversaries — and one clearer path to the market leader that has driven the EV transition from the start.
For Tesla, this is more than regulatory relief. It is a strategic tailwind that reinforces its position as America’s premier EV innovator at a time when domestic manufacturing and technological independence matter most.
Tesla Cybercab stands to gain from new rules that the Trump Administration is aiming to enforce on autonomous vehicles. On Thursday, NHTSA, under the Trump Administration’s U.S. Department of Transportation, commenced rulemaking on the Federal Motor Vehicle Safety Standards (FMVSS).
This effort aims to eliminate the mandate for manual brake pedals in vehicles that are designed to be driven exclusively by automated driving systems. This would impact the Tesla Cybercab, which the company has stated would operate without a steering wheel or pedals.
Tesla Cybercab launch is imminent after latest sighting at Giga Texas
The Trump Administration is looking to revise FMVSS No. 135, which requires standard braking systems on light-duty vehicles.
Currently, the regulation requires light-duty cars to use traditional manual braking systems that allow operators to slow the vehicle. With the advent of self-driving in the U.S., these regulations need updating, and these are the changes that could come to FMVSS No. 135:
- Removes requirements for hand- or foot-operated brake controls for vehicles designed never to be operated by a human. Existing rules still apply to AVs that retain manual controls.
- All subject vehicles must still meet the same stopping distance performance criteria via alternative testing procedures.
- While this update ensures AVs can physically stop when commanded, NHTSA is separately developing safety performance requirements for AVs in real-world driving scenarios.
- NHTSA will continue to use its broad defect enforcement authority to investigate unsafe ADS behavior and oversee recalls.
As autonomy becomes a greater part of passenger travel, these types of rule adjustments will be more than reasonable. It will give manufacturers the ability to self-certify their vehicles and avoid any red tape that could ultimately delay the deployment of these vehicles.
Administrators are also incredibly excited about the opportunity to play a role in the advancement of self-driving vehicles.
“We are at the cusp of the greatest technological revolution in vehicle technology since the innovation of the Model T,” NHTSA Administrator Jonathan Morrison said. “If we want America to lead the way, we have to reimagine our regulatory framework. That’s why under Secretary Sean Duffy’s AV Framework, NHTSA is tearing down pointless barriers to innovative designs while strengthening the fundamental safety requirements that matter and holding AV developers accountable for safe performance.”
The Cybercab entered mass production at Gigafactory Texas in April. Tesla ultimately plans to push the vehicle into its Robotaxi fleet, potentially when frameworks like these are established.
Tesla plans to boost production at its Gigafactory Berlin plant in Germany following a sharp rebound in sales and demand in Europe after a softer 2025.
The plans put Tesla in a better position to compete with strengthening companies in Europe and potentially other markets; demand indicators show Tesla is much better off than in 2025.
Last year was a tough year for Tesla in terms of overall demand in Europe. The company produced over 200,000 vehicles at the German plant last year, a soft figure compared to the 375,000 vehicles Tesla lists as its current capacity at the factory.
🚨 Tesla said this morning it will ramp up production at Gigafactory Berlin to a volume of 7,500 vehicles per week.
This is a 20 percent boost in production. Tesla will hire 1,000 new employees to help with the increase.$TSLA pic.twitter.com/kravKfRO5n
— TESLARATI (@Teslarati) June 25, 2026
Tesla’s overall European sales dropped significantly last year due to a variety of factors. However, sales are rebounding, and demand is strong once again, and only getting stronger. Tesla is now planning to bump production of Model Y vehicles at Giga Berlin upward by about 20 percent. It will also bring 1,000 new jobs to the plant.
Tesla confirmed the details of its planned production expansion in Germany this morning. It is a strategy to keep up with strengthening demand.
In Q1, Tesla saw a record 61,000 vehicles produced at Giga Berlin. European registrations rebounded sharply, with Model Y seeing 117 percent increases in March 2026 compared to last year. Germany alone saw stark increases, with a quadrupling in registrations to 9,252 units.
This trend continued in other key European markets, including France, Denmark and Sweden. Tesla registrations were up over 46 percent in some of these markets, and Model Y continued its trend as a top BEV in the market.
Demand has been recovering strongly in 2026, giving Tesla a reason to expand production efforts at the factory. These increases signal management’s confidence in sustained or growing European pull for Berlin-built vehicles.
One of Tesla’s biggest threats just got banned in the U.S.
Tesla Cybercab stands to gain from new Trump autonomy rules
