HOUSTON – Conductive additives only make up a small portion of a battery electrode, yet they play a significant role in battery performance. Many manufacturers are unaware of the latest developments in the rapidly evolving industry.
Ahead of The Battery Show Detroit 2026 on Oct. 12-15, Orion S.A.’s battery experts highlighted five trends that are reshaping the role of conductive additives in lithium-ion batteries and other energy storage technologies:
Conductive additives do more than provide electronic conductivity. They are increasingly recognized as critical components of electrode design rather than simple conductivity enhancers. Researchers and manufacturers are paying close attention to how they shape electrode microstructure, thereby impacting pore channels, electrolyte distribution and ionic transport within the electrode. To be sure, their primary role is to create a continuous three-dimensional conductive network that enables electrons to move efficiently between the active material particles and from there to the current collector and vice versa. This conductive backbone supports consistent electron transport throughout cycling, enabling higher active-material utilization, improved rate capability and more reliable long-term operation. Optimizing these factors together offers unique opportunities to improve battery performance beyond the obvious enhancement of electronic conductivity, including improved active material utilization, rate capability and cycling performance.
Performance requirements are becoming more demanding. The transition to faster-charging electric vehicles, higher-energy-density cells and longer-lasting energy storage systems is
raising performance expectations for conductive additives. Manufacturers are seeking materials that combine electrical conductivity, low impurity levels, consistent quality and sustainable production. As battery designs become more demanding, conductive additives are expected to play an increasingly important role in helping cell manufacturers achieve both performance and reliability targets. A broad portfolio that includes carbon black made with the furnace, lamp and acetylene processes is important for meeting the diverse requirements of different battery technologies.
Hybrid conductive systems are becoming more common. Combining carbon black with carbon nanotubes, these systems offer complementary benefits in conductivity and mechanical resilience. As new cell formats and active materials emerge, the ability to engineer conductive networks for specific chemistries is becoming a key area of focus. Orion has invested in a fully equipped battery laboratory to help customers tailor these combinations to specific chemistries and performance targets.
Automotive quality standards are reaching deeper into the battery supply chain. Historically, chemical companies have followed their own industry standards. But today, conductive carbons are increasingly subject to stricter cleanliness requirements, more rigorous traceability and advanced analytical methods capable of detecting trace metallic contaminants. In response, Orion recently completed a rigorous qualification process for IATF 16949 – the auto industry’s seal of approval for quality – at its conductive additives plant in Berre-l’Étang, France.
Dispersion expertise can be as important as material selection. Slurry preparation is a critical step in electrode manufacturing, where material properties, interactions between formulation components and mixing conditions must be considered together. Carbon black plays a major role in slurry rheology, making its selection an integral part of optimizing the overall formulation and process. Balancing these factors supports effective dispersion and consistent electrode production. Through its battery applications laboratory, Orion works with customers to optimize formulations for lithium-ion, lead-acid and emerging battery technologies. By combining expertise in conductive additive design, selection and dispersion with customers’ performance requirements, the company aims to accelerate battery development and support the creation of differentiated energy storage solutions.
Orion experts will be available to discuss these trends and several other industry developments at booth #2942 at The Battery Show Detroit 2026.
EDITORS: Images of Orion’s acetylene-based conductive additives and its acetylene black facility Berre-l’Étang, France, can be downloaded from the Image Gallery on Orion’s website: https://orioncarbons.com/news/image-gallery/
About Orion S.A.
Orion S.A. (NYSE: OEC) is a leading global supplier of carbon black, a solid form of carbon produced as powder or pellets. The material is made to customers’ exacting specifications for tires, coatings, ink, batteries, plastics and numerous other specialty, high-performance applications. Carbon black is used to tint, colorize, provide reinforcement, conduct electricity, increase durability and add UV protection. Orion has four innovation centers and produces carbon black at 15 plants worldwide, offering the most diverse variety of production processes in the industry. The company’s corporate lineage goes back more than 160 years to Germany, where it operates the world’s longest-running carbon black plant. Orion is a leading innovator, applying a deep understanding of customers’ needs to deliver sustainable solutions. For more information, please visit orioncarbons.com.
Contact:
William Foreman
Orion S.A.
Director of Corporate Communications and Government Affairs
william.foreman@orioncarbons.com
Direct: +1 832-445-3305
