San Jose, CA-based startup Lyten today announced plans to invest more than $1 billion to build the world’s first lithium-sulfur battery gigafactory. The facility of the self-described “supermaterial” applications company and global leader in lithium-sulfur batteries, will be located near Reno, NV, and have the capability to produce up to 10 GW·h of batteries annually at full scale.

“Today is the latest milestone in Lyten’s nine-year history,” said Dan Cook, Lyten’s Co-Founder and CEO. “Lithium-sulfur is a leap in battery technology, delivering a high-energy-density, lightweight battery built with abundantly available local materials and 100% U.S. manufacturing.”

Lyten’s factory will manufacture cathode active materials (CAMs), lithium metal anodes, and complete assembly of lithium-sulfur battery cells in cylindrical and pouch formats. The company has been manufacturing CAM and lithium metal anodes and assembling batteries at its semi-automated pilot facility in San Jose, CA, since May 2023. Phase 1 of the facility is scheduled to come online in 2027.

“Nevada has been our preferred location from the start,” added Celina Mikolajczak, Lyten’s Chief Battery Technology Officer. “We have continuously felt welcomed by the leaders of Reno and Washoe County. We need a talented, innovative workforce and this partnership will deliver just that.”

Nevada is emerging as a key hub for U.S. battery manufacturing. Key facilities include Tesla’s Gigafactory Nevada and one of the world’s largest lithium-ion battery factories by Panasonic Energy of North America; Dragonfly Energy for lithium-cell chemistries and advanced pack design. Others there are from Lithion Battery producing batteries, battery packs, and energy storage systems; Ultion Technologies for lithium cells and components; Rechargeable Power Energy North America for rechargeable energy solutions; Entek Manufacturing for battery separators for lithium batteries; and Quantum Copper that produces a non-toxic fire-resistant polymer that makes lithium batteries safer.

“Lyten’s choice to build the world’s first lithium-sulfur battery gigafactory here underscores the strategic advantages our state offers to leading tech companies,” said Nevada Governor Joe Lombardo. “With our robust infrastructure and skilled workforce, Nevada is well-positioned for continued growth and job creation well into the future.”

Lyten says its high-energy-density lithium-sulfur cells will enable up to 40% lighter weight than lithium-ion and 60% lighter weight than lithium iron phosphate (LFP) batteries. The company’s cells are fully manufactured in the U.S. and use abundantly available local materials, eliminating the need for the mined minerals nickel, cobalt, manganese, and graphite. Its use of low-cost, local materials makes lithium-sulfur a lower-cost battery than lithium-ion at scale.

The company’s lithium-sulfur batteries are entering the micromobility, space, drone, and defense markets in 2024 and 2025. The Nevada gigafactory is part of Lyten’s strategy to meet the demand from a pipeline expected from “hundreds of potential customers.”

The planned 1.25-million-ft² facility, located on a 125-acre campus in the Reno AirLogistics Park, will initially employ 200 people, growing to more than 1000 at full capacity, including researchers, manufacturing engineers, battery engineers, technicians, and operators.

Lyten has signed an MOU with industrial developer Dermody Properties to locate the facility on land owned by the Reno-Tahoe Airport Authority. The battery startup is also working with local universities, including the University of Nevada-Reno (UNR) and Truckee Meadows Community College as well as the Nevada Native American and Tribal members to train the workforce required to scale the gigafactory operations.

Founded in 2015, Lyten has received more than $425 million in investment from companies including Stellantis Ventures, FedEx, Honeywell, Walbridge, the European Investment Fund, and the Luxembourg Future Fund.

The company’s processes permanently sequester carbon from methane in the form of 3D graphene and it uses the tunable supermaterial to develop decarbonizing applications. It is currently commercializing next-generation lithium-sulfur batteries for use in the transportation, aerospace, space, consumer electronics, and energy storage markets; next-generation high strength, low carbon footprint composites; and next-generation sensors that significantly increase detection sensitivity and selectivity for use in environmental, automotive, industrial, health, and supply chain applications.

We last covered Lyten in February in our article on the Halcyon four-door concept that previewed Chrysler’s car revival. The concept car envisions incorporating the startup’s 800-V lithium-sulfur EV batteries that do not use nickel, cobalt, or manganese. The resulting solution is said to have an estimated 60% lower carbon footprint than today’s best-in-class batteries and a pathway to achieve the lowest emissions EV battery on the global market.

In May 2023, the Stellantis Ventures corporate venture fund announced an investment in Lyten to accelerate the commercialization of the supplier’s 3D graphene applications for the mobility industry.