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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Evidence of a toroidal magnetic field in the core of 3C 84

The spatial scales of relativistic radio jets, probed by relativistic magneto-hydrodynamic (RMHD) jet launching simulations and by most very long baseline interferometry (VLBI) observations differ by an order of magnitude. Bridging the gap between these RMHD simulations and VLBI observations requires selecting nearby active galactic nuclei (AGN), the parsec-scale region of which can be resolved. The radio source 3C 84 is a nearby bright AGN fulfilling the necessary requirements: it is launching a powerful, relativistic jet powered by a central supermassive black hole, while also being very bright. Using 22 GHz globe-spanning VLBI measurements of 3C 84 we studied its sub-parsec region in both total intensity and linear polarisation to explore the properties of this jet, with a linear resolution of ~0.1 parsec. We tested different simulation set-ups by altering the bulk Lorentz factor Γ of the jet, as well as the magnetic field configuration (toroidal, poloidal, helical). We confirm the persistence of a limb brightened structure, which reaches deep into the sub-parsec region. The corresponding electric vector position angles (EVPAs) follow the bulk jet flow inside but tend to be orthogonal to it near the edges. Our state-of-the-art RMHD simulations show that this geometry is consistent with a spine-sheath model, associated with a mildly relativistic flow and a toroidal magnetic field configuration.

3C 84 (NGC 1275)↗
DOE OSTI2024

N-S3 Cellular Vehicle-to-Everything (C-V2X) Cosimulation Framework [SWR-24-54]

This is a vehicular networking simulator designed to enable synchronized network simulation with vehicle traffic simulation software. The communications model is based on the 3GPP LTE-V2X Mode 4 protocol, but includes several other wireless network protocol models as well. This simulator includes both a V2X network simulation implemented in ns-3 as well as an interface to automatically configure, run, and interact with a set of ns-3 instances based on network size and available hardware. This software has been tested with Aimsun NEXT 2.0 simulator (with V2X SDK), but uses a generic interface for compatibility with any comparable vehicle traffic simulator across the HELICS co-simulation framework. This software is intended as a generalized extension to vehicle traffic simulation, and does not model any vehicle traffic on its own.

Wang, Qichao↗
DOE OSTI2024

Investigation of Numerical Methods for Performance Improvement of MOOSE-based System Analysis Codes

The main objective of this study is to investigate the feasibility of implementation of staggered-grid finite volume method (SG-FVM) using the MOOSE framework to support the development of the advanced system analysis code SAM. This study successfully demonstrated the integration of staggered-grid finite volume method in the application level using the MOOSE framework, although not in the framework level which should be investigated in the future. Several important properties of the implemented SG-FVM, e.g., high-order spatial accuracy and monotonicity preserving, have been demonstrated with selected numerical test cases. The superior performance in execution time was also evident based on a selected one- dimensional flow problem in a loop configuration.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Assessing the Impact of Large Removable Beryllium Reflector Experiments on HFIR Performance and Safety Metrics

This study investigated the effect of various removable beryllium (RB) experiment configurations on High Flux Isotope Reactor (HFIR) metrics to address increasing interest in these facilities for materials and fuels irradiation research. The RB reflector contains eight large and four small irradiation experiment facilities that offer excellent neutron flux conditions to perform fission and fusion reactor materials and fuels irradiation research. This work aims to outline acceptable RB configurations based on safety, performance, and programmatic metrics. This study assessed experiment effects on reactivity, cycle length, fission rate density distributions, and neutron flux distributions using the Shift, HFIRCON, and SCALE ORIGEN codes. Initial evaluations focused on generic experiment materials including aluminum plugs, stainless steel plugs, molybdenum plugs, and aluminum plugs with gadolinium shields. Subsequent analyses of MiniFuel experiments were performed to evaluate a heterogenous experiment, consisting of a more complex geometry and bearing several materials, and to test the correlations developed with the generic materials on a real experiment. Furthermore, the effects of neutron poison concentrations in the standard beryllium plugs were evaluated. When assuming a reference RB configuration with eight large fresh beryllium plugs, perturbed configurations with three aluminum plugs, one stainless steel plug, one molybdenum plug, one gadolinium-shielded aluminum plug, and one MiniFuel experiment resulted in a cycle length reduction of less than 1.3 days, the current threshold before requiring additional approvals. Configurations with five aluminum plugs, one stainless steel plug, one molybdenum plug, one gadolinium-shielded aluminum plug, and two MiniFuel experiments meet the 1.3 day limit if irradiated beryllium plugs are considered. Fuel element fission rate density distributions remained within safety limits, with maximum local increases under 9%. Neutron flux calculations revealed large thermal flux depressions inside and around the perturbed RB facilities, while epithermal and fast neutron fluxes increased because of reduced neutron moderation by the perturbed materials. These findings provide valuable guidance for optimizing RB configurations to balance safety and performance at HFIR.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Preliminary Plan to Inform Testing of a Heat Exchanger Test Article

This report presents a preliminary plan to guide the qualification testing of advanced heat exchanger (HX) components for nuclear-to-industrial heat transfer applications. The objective is to establish a defensible, physics-based methodology that integrates computational modeling, targeted experimentation, and in-service inspection considerations to demonstrate component performance and reliability under representative reactor conditions. The analysis identifies Sodium-cooled Fast Reactor (SFR) and High-Temperature Gas-cooled Reactor (HTGR) systems as reference configurations in terms of temperature, pressure, and chemical environment. Within these operating envelopes, dominant degradation mechanisms— including creep–fatigue interaction, flow-induced vibration, corrosion, and diffusion-bond deterioration—were evaluated to define test requirements. A comprehensive computationalexperimental framework is proposed to support life prediction and qualification activities. The framework couples high-fidelity structural-mechanics, thermal-hydraulic, and fluid-structure interaction models with accelerated degradation testing to produce a traceable linkage between microstructural evolution, mechanical performance, and remaining useful life (RUL). The approach adheres to established Verification, Validation, and Uncertainty Quantification (VVUQ) standards (ASME V&V 10/20; NUREG-2152) and incorporates a digital-twin architecture for continuous model refinement through data assimilation. The plan further outlines testing methodologies, including pre-test analyses, test-loop design parameters, and sensor placement strategies that maximize information yield while maintaining mechanistic fidelity. Complementary sections describe in-service inspection (ISI), on-line monitoring (OLM), and structural-health-monitoring (SHM) techniques applicable to compact HX geometries typical of advanced reactors. Collectively, these activities establish the technical foundation for demonstrating 40-60-year equivalent service life of advanced heat exchangers in support of the U.S. Department of Energy’s Advanced Reactor and Integrated Energy Systems programs. The forthcoming phase will execute the defined pre-test analyses, initiate hardware fabrication, and implement the integrated testing campaign to validate the proposed qualification methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

An Analysis of Input Parameters for Film-Based Flash X-Ray Radiography

Flash X-ray radiography (flash) is a commonly used diagnostic technique in dynamic experiments. An analysis of the effects of input parameters on resulting metrics of image quality can aid the experimentalist in configuring the X-ray input parameters to produce the highest quality radiograph for a given experiment. Here, a flash X-ray test bed with HS800 film and a LANEX Medium F intensifier screen was used with an L3 450 kVp pulser and Scandiflash X-ray tube for this study. Input parameters including charge voltage, source filtering, and film-pack assembly were investigated for their impact on contrast-to-noise ratio (CNR), contrast, and contrast transfer function (CTF). Using VIDAR’s NDT Pro industrial film digitizer, scanner parameters such as optical density range, pixel spacing, scan mode, and digital bit-depth were also examined for their impact on image quality metrics. The highest CNR values were found with two LANEX intensifiers and no filtering. Charge voltage had no direct impact on CNR values. LANEX screen count and filtering resulted both in direct effects on CNR and interaction effects with each other and CNR value. Uncertainty bounds for CNR comparisons and repeatability of CTF evaluations are also discussed. Finally, the film results are compared with a previous study using other detector types, specifically Carestream INDUSTREX Flex GP, Flex HR, Flex XL Blue, and HPX-DR 3543.

dynamic radiography↗
DOE OSTI2026

Thermal Gradient Effects on Redox Evolution and Volatility-Driven Fractionation in Ternary U/Ce/Cs Condensates

Understanding how thermal history influences redox evolution and chemical fractionation is essential for characterizing high-temperature condensation in complex materials, including nuclear debris. Here, we tested the hypothesis that distinct thermal regimes in a plasma flow reactor influence redox pathways and elemental partitioning in ternary U/Ce/Cs systems. A configurable plasma flow reactor was modified with an external tube furnace to impose two distinct thermal gradients: continuous ambient cooling and a furnace-assisted thermal hold-up near 1400 K followed by rapid cooling. Transmission electron microscopy characterized phase identity, morphology, and nanoscale element distributions, while inductively coupled plasma-mass spectrometry quantified bulk elemental ratios. Across both thermal regimes, uranium and cerium condensed as UO 2 and CeO 2 as dominant refractory oxide products. Uranium partially oxidized to α-UO 3 during extended ambient cooling, while furnace-assisted hold-up preserved UO 2 and produced partial reduction of cerium to Ce 2 O 3 . Cesium remained volatile upstream and condensed later in the reactor, forming Cs 2 O and Cs-uranate phases with the highest incorporation after thermal hold-up. Bulk ICP-MS measurements supported these observations. U/Ce ratios remained comparatively stable and Cs displayed delayed and apparent transient enrichment that matched the nanoscale measurements. This integrated approach provides a quantitative method for linking thermal gradients to redox evolution and volatility-driven fractionation. These results show how the plasma flow reactor can identify where equilibrium descriptions remain adequate and where kinetic effects from residence time and temperature history must be considered when interpreting condensation behavior in multicomponent systems.

and nuclear chemistry↗
DOE OSTI2025

Engineering Polyketide Stereocenters with Ketoreductase Domain Exchanges

Polyketide synthases (PKSs) are versatile biosynthetic megasynthases capable of producing a diverse range of natural products with many applications, including in pharmaceuticals. The stereochemical precision of PKSs makes them a powerful tool for engineering tailored, unnatural polyketides; however, modifying the stereocenters of a PKS product while maintaining production levels remains a significant challenge. In this study, we systematically tested and evaluated strategies for ketoreductase (KR) domain exchanges, the domain responsible for setting stereocenters of polyketide products. After first optimizing the method for KR exchanges, we then performed 44 KR domain exchanges on three different PKSs to obtain high production of all four stereoisomers in vivo. By testing both one- and two-module PKS systems, we investigated how downstream modules process intermediates with altered stereochemistry and found that the configuration of the α-substituents was critical for gatekeeping by the ketosynthase (KS). To overcome this constraint, we investigated two different strategies for altering the KS domain, including introducing targeted mutations in the downstream KS, and exploring boundaries in exchanging the entire functional unit from the donor PKS. Both strategies successfully modified the KS stereocontrol with distinct trade-offs; the functional unit exchange resulted in higher titer improvements, though it was more likely to break the entire PKS. This study demonstrates a comprehensive approach to successfully engineering all four stereochemical configurations in multiple PKS systems, advancing our understanding of and ability to rationally modify polyketide stereochemistry through multiple engineering strategies.

Keiser, Leah S. [Joint BioEnergy Institute (JBEI),↗
DOE OSTI2025

Multilayer Electrodes with Metalized Polymer Current Collector for High-Energy Lithium-Ion Batteries with Extreme-Fast-Charging Capability

The pursuit of batteries capable of extreme fast charging (XFC), that also satisfy high energy and safety criteria, poses a significant challenge to current lithium-ion battery technologies. Additionally, the increasing demand for aluminum (Al) and copper (Cu) in electrification, and vehicle light weighting is driving these metals towards near-critical status in the medium term. This study introduced metalized polymer films by depositing an Al or Cu thin layer onto two sides of a polyethylene terephthalate (PET) film – named mPET/Al and mPET/Cu, as lightweight, cost-effective alternatives to traditional metal current collectors in LIBs. We have utilized current collectors that significantly reduce weight (by 73%), thickness (by 33%), and cost (by 85%) compared to traditional metal foil counterparts. We conducted an extensive evaluation of their mechanical and electrical properties, including in-plane and through-plane resistivities, affirming their suitability for the roll-to-roll battery manufacturing process. Additionally, a novel XFC testing protocol was employed to thoroughly assess the cells' (both half and full-cell) performance across various C-rates and under long-term tests. These advancements have the potential to enhance energy density to 280 Wh/kg at the electrode level under 10-minute charging at 6C. Through testing, including a novel XFC protocol across various C-rates and long-term cycling (up to 1000 cycles) in different cell configurations, we have demonstrated the superior performance of these metalized polymer films. Notably, mPET/Cu and mPET/Al foils exhibited comparable capacities to conventional cells under XFC, with the mPET cells showing a 27% improvement in energy density at 6C and maintaining significant energy density after 1000 cycles. This study underscored the potential of mPET foils to revolutionize the roll-to-roll battery manufacturing process and significantly advance the performance metrics of LIBs in EV applications. Moreover, our results suggest that there is potential to enhance the performance of mPET foils, especially mPET/Al, by optimizing the manufacturing process to achieve higher conductivity.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Bounding Pressure and Flammability Evaluations of Aluminum-Clad Spent Nuclear Fuel Department of Energy Standard Canisters

This paper presents bounding pressure and flammability evaluations for DOE Standard Canister loaded with DOE-managed aluminum-clad spent nuclear fuel (ASNF). The objective of these evaluations is to gain confidence in the safety and feasibility of possible loading configurations for extended (>50 years) periods of dry storage, with particular focus on the dry storage canister pressures and potential for formation of a flammable atmosphere. The primary concern about the extended dry storage of ASNF is radiolytic gas generation. The aluminum cladding of these materials tends to corrode, and these corrosion products—typically aluminum oxides, such as boehmite, bayerite, or gibbsite—could carry water. This makes ASNF dry storage canisters difficult to dry. The gamma radiation field in dry storage environments could cause a radiolytic breakdown of residual water, forming chemical species such as molecular hydrogen (H2). The release of these species could increase the canister pressure and lead to the generation of a flammable canister atmosphere. The bounding evaluations presented within this study surmise conservative, but credible, conditions and processes. This includes the assumption of a full breakdown of a large quantity of free, physisorbed, and chemisorbed water (bound in a trihydrate, i.e., Al2O3 • 3H2O, layer). The considered dry storage configurations include a ~3 m (10 ft) long, ~46 cm (18 in) diameter (10 x 18) DOE Standard Canister loaded with 32 Advanced Test Reactor (ATR) ASNF elements, and a ~3 m (10 ft) long, ~61 cm (24 in) (10 x 24) diameter DOE Standard Canister loaded with 40 ATR ASNF elements. While the results of this study indicate the possibility of atmospheric hydrogen concentrations above the lower flammability limit, insufficient concentrations of oxygen will prevent the formation of flammable atmospheres. The maximum credible pressures remain well within the structural limits of the DOE Standard Canister.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Laser Powder Bed Fusion Manufactured Alloys 625 and 282 and Properties Relevant to Advanced Nuclear Components

Under the Advanced Materials and Manufacturing Technologies program, two Ni-based alloys fabricated by laser powder bed fusion (LPBF) have been evaluated: γ′-strengthened Haynes 282 and solution-strengthened Inconel 625. Large printing defects were observed in the LPBF 282 alloy fabricated using a Renishaw AM250 machine, likely due to particle spattering during printing. Annealing at 1,180°C for 1 h followed by 4 h at 800°C in a high density of 50 nm γ′-strengthening precipitates as well as partial recrystallization resulted in a bimodal grain distribution. Creep testing performed at 750°C revealed lower creep life and ductility for the LPBF 282 compared with wrought 282. X-ray computed tomography combined with optical and scanning electron microscopy microstructural characterization revealed crack formation during creep testing, initiated either from printing defects or from creep cavitation at grain boundaries. Printing defects were the likely reason for the lower creep performance of LPBF 282 and could be suppressed by optimizing the build configuration. Printing 625 on an EOS M290 machine using the recommended EOS parameters resulted in a very low defect density. Superior creep strength at 725°C was observed for the as-printed LPBF 625 along the build direction when compared with wrought 625. No defect larger than ~50 µm could be detected by X-ray computed tomography in the as-printed conditions and after creep testing for 1,000 h at 725°C and 150 MPa. Small, needle-like δ-phase precipitates were observed after creep testing for 100 h at 725°C and 200 MPa. The rapid formation of the γ phase is directly related to the initial Nb and Mo segregation in the LPBF 625 cell walls, and its effect on the alloy’s high-temperature performance will be evaluated. Solution annealing was carried out at 1,150°C for 1 h and led to full recrystallization of the alloy. A decrease in strength and increase in ductility were observed after solution annealing, and the alloy recrystallization resulted in isotropic tensile properties at room temperature, contrary to what was observed for the as-printed LPBF 625.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Tetris-inspired detector with neural network for radiation mapping

Abstract Radiation mapping has attracted widespread research attention and increased public concerns on environmental monitoring. Regarding materials and their configurations, radiation detectors have been developed to identify the position and strength of the radioactive sources. However, due to the complex mechanisms of radiation-matter interaction and data limitation, high-performance and low-cost radiation mapping is still challenging. Here, we present a radiation mapping framework using Tetris-inspired detector pixels. Applying inter-pixel padding for enhancing contrast between pixels and neural networks trained with Monte Carlo (MC) simulation data, a detector with as few as four pixels can achieve high-resolution directional prediction. A moving detector with Maximum a Posteriori (MAP) further achieved radiation position localization. Field testing with a simple detector has verified the capability of the MAP method for source localization. Our framework offers an avenue for high-quality radiation mapping with simple detector configurations and is anticipated to be deployed for real-world radiation detection.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Underwater unexploded ordnance discrimination based on intrinsic target polarizabilities – A case study

Seabed unexploded ordnance that resulted partly from the high failure rate among munitions from more than 80 years ago and from decades of military training and testing of weapons systems poses an increasing concern all around the world. Although existing magnetic systems can detect clusters of debris, they are not able to tell whether a munition is still intact requiring special removal (e.g. in situ detonation) or is harmless scrap metal. The marine environment poses unique challenges, and transferring knowledge and approaches from land to a marine environment has not been easy and straightforward. On land, the background soil conductivity is much lower than the conductivity of the unexploded ordnance and the electromagnetic response of a target is essentially the same as that in free space. For those frequencies required for target characterization in the marine environment, the seawater response must be accounted for and removed from the measurements. The system developed for this study uses fields from three orthogonal transmitters to illuminate the target and four three-component receivers to measure the signal arranged in a configuration that inherently cancels the system's response due to the enclosing seawater, the sea–bottom interface and the air–sea interface for shallow deployments. The system was tested as a cued system on land and underwater in San Francisco Bay – it was mounted on a simple platform on top of a support structure that extended 1 m below and allowed the diver to place metal objects to a specific location even in low-visibility conditions. The measurements were stable and repeatable. Furthermore, target responses estimated from marine measurements matched those from land acquisition, confirming that the seawater and air–sea interface responses were removed successfully. Thirty-six channels of normalized induction responses were used for the classification, which was done by estimating the target principal dipole polarizabilities. Our results demonstrated that the system can resolve the intrinsic polarizabilities of the target, with clear distinctions between those of symmetric intact unexploded ordnance and irregular scrap metal. The prototype system was able to classify an object based on its size, shape and metal content and correctly estimate its location and orientation.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2024

Embedded FPGA developments in 130 nm and 28 nm CMOS for machine learning in particle detector readout

Embedded field programmable gate array (eFPGA) technology allows the implementation of reconfigurable logic within the design of an application-specific integrated circuit (ASIC). This approach offers the low power and efficiency of an ASIC along with the ease of FPGA configuration, particularly beneficial for the use case of machine learning in the data pipeline of next-generation collider experiments. An open-source framework called "FABulous" was used to design eFPGAs using 130 nm and 28 nm CMOS technology nodes, which were subsequently fabricated and verified through testing. The capability of an eFPGA to act as a front-end readout chip was assessed using simulation of high energy particles passing through a silicon pixel sensor. A machine learning-based classifier, designed for reduction of sensor data at the source, was synthesized and configured onto the eFPGA. A successful proof-of-concept was demonstrated through reproduction of the expected algorithm result on the eFPGA with perfect accuracy. Finally, further development of the eFPGA technology and its application to collider detector readout is discussed.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

PNNL-Predictive-Phenomics/ProteoMeter

ProteoMeter is a Python package that assists in the statistical analysis of global proteomics, protein post-translation modification (PTM), and limited proteolysis (LiP) data. It contains batch correction, normalization, and statistical testing methods, as well as functions that "roll up" peptide-level data to the single-site level. It has a robust user configuration system, allowing it to flexibly integrate different types of experiment designs. For basic usage, a simple configuration file provides the essential functionality. Advanced users have access to the entire statistical pipeline for fine-tuning analyses. Processed data is easily exported to many common spreadsheet and data-frame formats.

Rozum, Jordan [Pacific Northwest National Lab]↗
DOE OSTI2025

Flow Tradeoff Tool Setup Guide

The current version of the tool was designed and tested on Windows 10 and Windows 11. When upgrading from a previous version, users will be prompted to choose whether to retain the existing configuration and database if using the same installation path.

13 HYDRO ENERGY↗
DOE OSTI2024

Performance of cross-flow turbines with varying blade materials and unsupported blade span

Cross-flow turbines could play a larger role in the diversification of the global energy supply if the impact of more cost-competitive design choices on performance and rotor dynamics was better understood. This study focuses on rotor performance and blade strain measurements while varying the following parameters: blade materials and blade free end length by changing strut support position. Towing tank experiments were performed with a modular 1-meter diameter cross-flow turbine consisting of three NACA 0018 blades with two support struts. One strut was fixed at the lower end of the turbine, while the second strut was adjustable, thereby changing the length of the free end. The blade materials tested were carbon, E-glass, and hollow E-glass fiber composites, in decreasing order of stiffness and cost. High-resolution distributed fiber optic sensors were embedded in two of the three rotor blades for each material and provided hundreds of strain measurements per blade. Turbine performance and blade strain were measured while varying tow speed and tip speed ratio. Performance tests were conducted at towing speeds sufficiently high for the performance to be independent of Reynolds number. E-glass blades and carbon blades performed similarly for the most rigid strut configurations. Higher strain was measured on the E-glass blades, and their performance was reduced for less rigid configurations compared to the carbon fiber blades. The performance of the highly deflective hollow E-glass blades was lower overall and became even more degraded for longer unsupported blade span. Furthermore, the results provide insight into the use of various blade materials in cross-flow turbines and guidance on allowable free end length for each material type.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

Metalized Polymer Current Collector for High-Energy Lithium-Ion Batteries with Extreme Fast-Charging Capability

Electric vehicles are pivotal in the global shift toward decarbonizing road transport, with lithium-ion batteries at the heart of this technological evolution. However, the pursuit of batteries capable of extremely fast charging that also satisfy high energy and safety criteria, poses a significant challenge to current lithium-ion batteries technologies. Additionally, the increasing demand for aluminum (Al) and copper (Cu) in electrification, solar energy technologies, and vehicle light-eighting is driving these metals toward near-critical status in the medium term. This study introduces metalized polythylene terephthalate (mPET) polymer films by depositing an Al or Cu thin layer onto two sides of a polyethylene terephthalate film—named mPET/Al and mPET/Cu, as lightweight, cost-effective alternatives to traditional metal current collectors in lithium-ion batteries. We have fabricated current collectors that significantly reduce weight (by 73%), thickness (by 33%), and cost (by 85%) compared with traditional metal foil counterparts. These advancements have the potential to enhance energy density to 280 Wh kg -1 at the electrode level under 10-min charging at 6 C. Through testing, including a novel extremely fast charging protocol across various C-rates and long-term cycling (up to 1000 cycles) in different cell configurations, the superior performance of these metalized polymer films has been demonstrated. Notably, mPET/Cu and mPET/Al films exhibited comparable capacities to conventional cells under extremely fast charging, with the mPET cells showing a 27% improvement in energy density at 6 C and maintaining significant energy density after 1000 cycles. This study underscores the potential of mPET films to revolutionize the roll-to-roll battery manufacturing process and significantly advance the performance metrics of lithium-ion batteries in electric vehicles applications.

25 ENERGY STORAGE↗