By Ankit SinghReviewed by Lexie CornerMar 31 2025The rapid rise of renewable energy and electric vehicles has driven demand for high-performance batteries with better efficiency, longer lifespan, and enhanced safety. However, conventional battery technologies face challenges like charge-discharge efficiency loss, electrode degradation, and limited cycle life.
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These issues often stem from material limitations, including poor ion transport, unstable electrode interfaces, and dendrite formation in metal-based anodes. Overcoming these barriers requires innovation in electrode design and surface modification.1
Metal surface engineering has emerged as a promising strategy to address these limitations. By tailoring the surface properties of battery electrodes, researchers can improve conductivity, mechanical stability, and charge retention. Techniques such as laser structuring, atomic layer deposition (ALD), and nano-patterning enable precise control at the micro- and nanoscale across different battery chemistries.
This article explores recent developments in metal surface engineering and how they are helping to enhance battery performance.1
Surface Texture Engineering
Surface texture engineering enhances electrode performance by optimizing micro- and nanoscale architectures to improve ion diffusion and electrochemical activity. Among these techniques, laser structuring has gained interest for its ability to generate precise hierarchical patterns on metal surfaces.1
One study published in Nanomaterials focused on improving silicon anodes for lithium-ion (Li-ion) batteries. Researchers used a femtosecond laser to texture copper foils, creating a hierarchical micro-nanostructure. This method helps mitigate the volume expansion of silicon, reducing issues like peeling and cracking while enhancing electron transfer.
The optimized anode achieved an impressive 80 % capacity retention after 300 cycles at a rate of 1 °C and 22 % retention at 3 °C, demonstrating excellent cycling stability and rate capability for next-generation energy storage.2
Chemical and plasma etching techniques offer scalable alternatives for surface modification. A study in Materials Letters used plasma etching the surface morphology of transition metal nitride (TMN) films for supercapacitor electrodes.
The surface of hafnium nitride (HfN) films was modified using argon and krypton plasma etching, which significantly increased both the specific surface area and capacitance. This advancement boosts conductivity, stability, and cycling performance, making TMN films ideal for flexible thin-film and on-chip micro-supercapacitors.3
Nano-patterning methods, like nanoimprint lithography, allow for the creation of uniform nanostructures that help reduce ionic resistance. A recent review article published in the Journal of Materials Research highlighted that nano-patterned surfaces can decrease the volume expansion of silicon electrodes during lithiation, as well as reduce mechanical degradation. This technique also increased the cycle life of electrodes used in batteries.4
Although the benefits of texture engineering are well documented, challenges remain. Surfaces that are too rough can accelerate electrolyte decomposition, while overly dense nanostructures may restrict ion mobility. Ongoing research is working toward design principles that balance surface area, structural integrity, and electrochemical performance.1
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Protective Coatings and Surface Treatments
Protective coatings are essential for shielding battery electrodes from corrosive reactions, interfacial instability, and mechanical wear.
Graphene-based coatings, in particular, have shown great promise due to their high electrical conductivity and impermeability. A recent study in ACS Applied Materials & Interfaces introduced a graphene-like carbon (GLC) coating on aluminum foil for high-rate Li-ion batteries.
This GLC coating effectively reduced interfacial resistance and enhanced electronic conductivity, adhesion, and electrochemical stability. As a result, it significantly extends the lifespan and efficiency of batteries, making GLC-coated aluminum foil a promising candidate for next-generation current collectors.5
ALD facilitates the conformal coating of ultra-thin films, such as aluminum oxide or titanium oxide, on complex electrode geometries. According to a study published in ACS, scientists developed lithium-rich layered oxide (LLO) cathodes using a TiO₂ and Al₂O₃ bilayer coating via low-temperature ALD.
This method improved capacity retention by over 90.4 % and achieved a specific discharge capacity of 146 mAh/g after 100 cycles at 1 °C. The coated electrodes showed reduced voltage decay, lower surface resistance, and improved charge transfer, significantly boosting battery stability and electrochemical performance.6
Another promising area of research involves the development of films compatible with the electrode of the battery, often referred to as artificial solid-electrolyte interface (SEI) layers. These coatings are engineered to maintain chemical stability within the electrolyte environment. They are also selectively permeable to lithium ions, allowing efficient ion transport. This promotes the formation of a uniform and stable SEI, which prevents further electrolyte decomposition and enhances overall battery performance.7
Despite these promising developments, scaling these coatings for commercial production remains a challenge. ALD and graphene synthesis are typically time-consuming and expensive, while polymer-based coatings can add unwanted weight.
To overcome these limitations, industry researchers are exploring roll-to-roll ALD systems and hybrid coating solutions that combine performance with manufacturability.4,5
Dendrite Suppression Through Surface Engineering
Dendrites are microscopic, needle-like structures that can form on the anode during charging. Their formation poses serious challenges to battery safety and contributes to capacity fade, particularly in high-energy-density systems.
Dendrites typically result from non-uniform metal deposition on the anode surface. This irregular growth can lead to internal short circuits, thermal runaway, and premature battery failure.8,9
Researchers have investigated various structured interfaces, such as three-dimensional current collectors with controlled pore sizes and surface morphologies, to promote a more uniform lithium deposition.
By reducing the local current density at the anode surface, these structures can effectively suppress the formation of dendrites. These engineered interfaces act as a template, encouraging lithium to plate in a more uniform, lateral manner, rather than forming sharp, elongated dendrites.8
Another approach involves the development of self-healing coatings that can repair any damage caused by dendrite penetration. These coatings often incorporate polymers or composite materials that can respond to mechanical stress or electrochemical changes.
When a dendrite attempts to grow through the coating, the self-healing mechanism activates, effectively blocking the dendrite's propagation and restoring the integrity of the separator, which prevents short circuits.9
The use of engineered metal alloys on the surface of anodes is also being explored as a way to modify their electrochemical properties. By alloying the surface with other elements, it is possible to influence the lithium deposition process and potentially inhibit dendrite formation.
Certain alloys might promote a more homogeneous nucleation and growth of lithium, resulting in a smoother and more uniform plating morphology, which is less prone to dendrite formation.9
Although these methods show promise in lab-scale demonstrations, their performance over extended cycling and varying temperature conditions remains under investigation.
Long-term durability and real-world scalability are critical challenges. Manufacturing complexity, cost, and integration with other battery components must also be addressed before these solutions can be adopted at a commercial scale.8,9
Zinc-Sponge Battery Electrodes That Suppress Dendrites l Protocol Preview
Future Outlook and Next Steps in Battery Engineering
Metal surface engineering continues to be a critical enabler in advancing battery technologies. By combining approaches such as surface texture optimization, protective coatings, and dendrite suppression, researchers are improving battery efficiency, extending lifespan, and enhancing safety.
The next phase of development will require a focus on scalable manufacturing techniques and integrated electrode designs that can accommodate multiple surface modifications without compromising performance or cost-effectiveness. These innovations support the growing demand for sustainable energy storage and electric transportation systems.
For more insights into battery research and manufacturing, explore our related articles:
References and Further Reading
- Lu, G., Nai, J., Luan, D., & Tao, X. (2023). Surface engineering toward stable lithium metal anodes. Science Advances. DOI:10.1126/sciadv.adf1550. https://www.science.org/doi/10.1126/sciadv.adf1550
- Wang, J. et al. (2022). Effect of Laser-Textured Cu Foil with Deep Ablation on Si Anode Performance in Li-Ion Batteries. Nanomaterials, 13(18), 2534. DOI:10.3390/nano13182534. https://www.mdpi.com/2079-4991/13/18/2534
- Gao, Z. et al. (2019). Enhanced capacitive property of HfN film electrode by plasma etching for supercapacitors. Materials Letters, 235, 148-152. DOI:10.1016/j.matlet.2018.10.032. https://www.sciencedirect.com/science/article/pii/S0167577X18315969
- Narita, K. et al. (2022). Additive manufacturing of 3D batteries: a perspective. Journal of Materials Research 37, 1535–1546. DOI:10.1557/s43578-022-00562-w. https://link.springer.com/article/10.1557/s43578-022-00562-w
- Li, X. et al. (2019). Suppressing Corrosion of Aluminum Foils via Highly Conductive Graphene-like Carbon Coating in High-Performance Lithium-Based Batteries. ACS Applied Materials & Interfaces, 11(36), 32826–32832. DOI:10.1021/acsami.9b06442. https://pubs.acs.org/doi/full/10.1021/acsami.9b06442
- Chen, W.-M. et al. (2024). Advanced TiO2/Al2O3 Bilayer ALD Coatings for Improved Lithium-Rich Layered Oxide Electrodes. ACS Applied Materials & Interfaces. DOI:10.1021/acsami.3c16948. https://pubs.acs.org/doi/full/10.1021/acsami.3c16948
- Zhang, S. et al. (2021). Achievement of high-cyclability and high-voltage Li-metal batteries by heterogeneous SEI film with internal ionic conductivity/external electronic insulativity hybrid structure. Energy Storage Materials, 40, 337-346. DOI:10.1016/j.ensm.2021.05.029. https://www.sciencedirect.com/science/article/pii/S2405829721002415
- Wang, J. et al. (2025). The challenges and strategies towards high-performance anode-free post-lithium metal batteries. Chemical Science. DOI:10.1039/d4sc06630h. https://pubs.rsc.org/en/content/articlehtml/2025/sc/d4sc06630h
- Aslam, M. K. et al. (2021). How to avoid dendrite formation in metal batteries: Innovative strategies for dendrite suppression. Nano Energy, 86, 106142. DOI:10.1016/j.nanoen.2021.106142. https://www.sciencedirect.com/science/article/pii/S2211285521003980
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