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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.
NASA has filed a procurement notice announcing its intent to add six post-certification missions to SpaceX’s existing Commercial Crew Transportation Capability contract. The agency said it would order up to three of those missions immediately upon adding them to the contract, with the remaining three available as needed through the end of the International Space Station’s planned operations in 2030.
The reason for the expansion is straightforward. NASA cited recently shortened ISS mission durations, technical issues and schedule delays encountered by Boeing, the allocation of missions between Boeing and SpaceX, and the ongoing technical challenges of maintaining a reliable crew transportation capability as the driving factors behind the decision. Boeing’s CST-100 Starliner has still not been certified for crewed flights, and a cargo-only Starliner mission was not included on NASA’s most recent mission manifest. With Boeing effectively sidelined for the foreseeable future, SpaceX is the only American company capable of rotating crews to the station.
The history behind this contract tells the fuller story of how SpaceX got here. NASA originally awarded SpaceX its Commercial Crew contract in 2014 for $2.6 billion. In 2022 NASA modified the contract to add five missions covering Crew-10 through Crew-14, worth $1.436 billion, bringing the total contract value at that point to $4.9 billion. The recent May 18 filing by NASA extends that runway further, with Crew-12 currently docked at the station and Crew-13 assigned and targeting a mid-September 2026 launch.
According to a report by SpaceNews, NASA stated in its filing: “It is necessary to award additional PCMs to SpaceX given the recently shortened ISS mission durations, technical issues and schedule delays encountered by Boeing, the allocation of missions between Boeing and SpaceX, NASA’s projections for when an alternative crew transportation system may become available, and the ongoing technical challenges of maintaining a reliable capability for crewed flights to ISS.”
No dollar value for the new six missions has been publicly confirmed yet, but based on the 2022 precedent of roughly $287 million per mission, the new block could represent close to $1.7 billion in additional contract value. With SpaceX simultaneously preparing Starship as NASA’s Artemis lunar lander, filing its S-1 for a June IPO, and now absorbing more ISS crew rotation work, the company’s role as the primary contractor for American human spaceflight is no longer a matter of circumstance. It is NASA policy.
In a notable intersection of Big Tech powerhouses, Meta, led by Mark Zuckerberg, has partnered with Canadian energy infrastructure giant Enbridge on a significant renewable energy initiative that will rely on battery technology from Elon Musk’s Tesla.
The project, which was announced this week, marks another step in Meta’s aggressive push to power its expanding data center operations with clean energy, dispelling many of the complaints people have about them.
This new development is located near Cheyenne, Wyoming, and will feature a 365-megawatt (MW) solar farm paired with a 200 MW/1,600 megawatt-hour (MWh) battery energy storage system, also known as BESS. Tesla is providing the batteries for the project, valued at roughly $200 million.
The story was originally reported by Utility Dive.
This Wyoming project represents the first phase of Enbridge and Meta’s joint “Cowboy Project.” Once operational, it will deliver power to Meta’s regional data centers through Cheyenne Light, Fuel, and Power under Wyoming’s Large Power Contract Service tariff.
This tariff, originally developed in collaboration with Microsoft and Black Hills Energy, is designed specifically for large loads like data centers. It ensures that the renewable supply serves hyperscale customers without impacting retail electricity rates for other users.
The battery system will operate under a long-term tolling agreement, providing dispatchable capacity that enhances grid reliability. During periods of high demand, the utility can access the backup generation, addressing one of the key challenges of integrating large-scale renewables with the explosive growth of data center electricity demand driven by artificial intelligence.
This latest collaboration builds on prior joint efforts between Enbridge and Meta in Texas, including the 600 MW Clear Fork Solar, 152 MW Easter Wind, and 300 MW Cone Wind projects. Together with the Wyoming initiative, the companies have now partnered on roughly 1.6 gigawatts (GW) of combined solar, wind, and storage capacity.
The deal highlights the intensifying demand for reliable, low-carbon power from technology giants. Meta has committed to supporting its data center growth with renewable energy, joining peers like Microsoft and Google in seeking large-scale solutions. Enbridge’s Allen Capps described the project as “one of the larger utility-scale battery installations supporting U.S. data center operations and growth.”
The involvement of Tesla’s battery technology adds an intriguing layer, linking two of the world’s most prominent tech leaders—Zuckerberg and Musk—in the clean energy transition.
As data centers continue to drive unprecedented electricity load growth across the United States, projects like this one illustrate how hyperscalers are turning to strategic partnerships with traditional energy players and innovative storage solutions to meet both sustainability goals and reliability needs.
SpaceX has decided to stand down from what was supposed to be the first test launch of Starship’s v3 rocket tonight after a minor issue with a hydraulic pin delayed the flight once more.
The company scrubbed its first test flight of the upgraded Starship v3 on May 21 in the final minutes of the countdown. SpaceX CEO Elon Musk quickly took to social media platform X, explaining that a hydraulic pin on the launch tower’s “chopsticks” arm failed to retract properly.
Musk added that the company would fix the issue this evening. SpaceX will attempt another launch tomorrow night at 5:30 p.m. CT, 6:30 p.m. ET, and 3:30 p.m. PT.
The hydraulic pin holding the tower arm in place did not retract.
If that can be fixed tonight, there will be another launch attempt tomorrow at 5:30 CT. https://t.co/DJAdvDYQpH
— Elon Musk (@elonmusk) May 21, 2026
The countdown for Starship Flight 12 — featuring the taller and more capable V3 stack with Booster 19 and Ship 39 — had been progressing smoothly until the late-stage issue surfaced. The Mechazilla tower arm, designed to secure the vehicle on the pad and eventually catch returning boosters, could not complete its retraction sequence.
SpaceX teams immediately began troubleshooting the hydraulic system for an overnight repair.
Starship V3 introduces several significant upgrades over earlier versions. These include greater propellant capacity, more powerful Raptor 3 engines, larger grid fins, enhanced heat shielding, and an improved fuel transfer system.
We covered the changes that were announced just days ago by SpaceX:
SpaceX unveils sweeping Starship V3 upgrades ahead of May 19 launch
The changes are intended to increase payload performance, support higher flight rates, and advance the vehicle toward operational missions, including Starlink deployments, NASA Artemis lunar landings, and future crewed Mars flights. The debut flight from Starbase’s new Launch Pad 2 marked an important milestone in scaling up the fully reusable Starship system.
This stand-down highlights the intricate challenges of preparing the world’s most powerful rocket for flight. Despite extensive pre-launch checks, a single component in the ground support equipment can force a scrub.
The incident aligns with Starship’s proven iterative development approach. Previous test flights have encountered both successes and setbacks, each providing critical data that refines hardware and procedures. Some outlets may call some of these flights “failures,” when in reality, they are all opportunities for SpaceX to learn for the next attempt.
With V3, SpaceX aims to reduce ground-system dependencies and increase launch cadence to meet ambitious long-term goals.
NASA just gave SpaceX more crew missions because Boeing can’t certify
Elon Musk called it Epic: The full story of SpaceX’s Starship Flight 12
