Conductive additives account for only a small fraction of a lithium-ion electrode, yet they have a significant influence on the electrical and mechanical behavior of electric vehicle (EV) cells. Their ability to control resistivity, support high-rate charge transport, and stabilize electrode structure becomes increasingly significant as EVs rely on higher power capability, faster charging, and tighter safety margins.
We recently spoke with two experts at Orion S.A.: Ana Kiricova, director of Commercial Development for Batteries at Orion S.A., and Dr. Michael Rohde, director of Global Marketing for Batteries at Orion S.A. Orion specializes in high-purity carbon materials used across battery chemistries in current and emerging cell architectures.
Together, Kiricova and Rohde bring a combined perspective that spans material science, product development, and the evolving production standards shaping automotive battery programs.
Conductive additives help maintain consistent electron pathways within EV cells, directly influencing power delivery, fast-charging behavior, and cycle life.
In this Q&A, they outline how conductive additives support electron transport, influence slurry rheology, enable high-rate capability, and affect cycle life. They also discuss the impact of carbon purity, particle structure, and dispersion quality on long-term cell behavior.
Additional topics include the requirements imposed by new cell formats, the growing use of blended additive systems, and the emergence of stricter automotive-grade qualification methods for carbon materials.
Here’s what they had to say…
Why are conductive additives such an important part of EV battery design, even though they make up only a small percentage of the electrode?
Ana Kiricova, director of Commercial Development for Batteries, Orion S.A.
Ana Kiricova (AK): Despite their small proportion of the electrode, conductive additives significantly influence the electrode’s volume resistivity. Without them, resistance rises, causing energy losses, heat generation and reduced fast-charging capability.
Conductive additives enable efficient charge transport and stable performance. In short, even in small amounts, they are essential for modern high-performance batteries.
Conductive additives also play a major role in shaping the slurry’s rheological profile, impacting manufacturability. Poorly optimized conductive additives can negatively affect battery performance, production efficiency and scrap rates.
What role does a conductive additive play inside a lithium-ion cell, and how does it influence charging, discharging, and overall power delivery?
AK: Conductive additives enable the active materials by forming a percolation (3D) electrically conductive network throughout the electrode matrix, which is critical for high-rate and high-power performance. They minimize particle-to-particle and particle-to-collector resistance, improving current distribution. Without them, cells would have a poor power performance and cell life.
Effective additives are engineered for high conductivity, optimal structure for percolation, manageable surface area and high purity to prevent cycle life degradation. In high-power applications, they help reduce polarization and enhance conductive pathways. High purity and optimized dispersion contribute to sustained high-rate performance over long cycle life.
How do the structure and purity of conductive carbon affect electron transport and cell performance?
AK: These factors are closely tied to the previous question. Structure and purity directly influence the formation of conductive networks and long-term stability, impacting both electron and electrolyte (can also use “ionic transport”) transport and overall cell performance.
What benefits do acetylene-based or other high-purity carbons offer compared to conventional furnace blacks?
AK: Acetylene-based carbons are considered premium additives for battery applications due to their engineered balance of high conductivity, exceptional purity and design flexibility.
In what ways can differences in carbon purity or particle structure impact conductivity and battery performance over time?
Dr. Michael Rohde, director of Global Marketing for Batteries, Orion S.A.
Michael Rohde (MR): Purity has no function in the cell, but is an important prerequisite for long cycle life and low defect rates. Particle structure has a functionality character in the electrode (as described above).
It forms a conductive network, reduces contact resistance, hosts electrolyte and therefore promotes the overall cell performance.
How might new cell formats, such as 4680 cylindrical cells or prismatic designs, change the performance requirements for conductive additives?
MR: New cell formats don’t change the fundamental electrochemical role of conductive additives, but they do change the mechanical and process boundary conditions under which the additive — as well the other components — has to perform.
First, the chemistry and final application remain the primary drivers for electrode design. They dictate mass loading, porosity and target electrode conductivity. Lower-conductivity cathodes (e.g. LFP, LMNO) and high-swelling anodes (e.g. Si-rich) will always require more robust conductive networks than better conductive active materials NMC/NCA, independent of format.
Conductive carbons must form networks that maintain conductivity without promoting brittleness and tolerate volume change without breaking percolation (graphite breathing, silicon expansion).
Carbon black must not have a negative impact on electrolyte filling. Its structure and dispersion should support a pore-size distribution that is compatible with fast and complete wetting. Conductive additives should support good adhesion and cohesion so that the electrode remains mechanically stable throughout coating, drying, calendering, winding/stacking and formation.
As EV batteries evolve toward higher energy density and faster charging, how are the needs for conductive additives changing?
AK: Advanced active materials place greater emphasis on additive effectiveness, meaning they need to provide the functionality even at lower loadings. In high-energy density applications, the active material in the slurry is maximized, but the dispersion quality cannot be compromised.
Fast-charging applications require highly conductive and well-structured additives hosting more electrolyte for supporting the ionic transport.
High-power charging capability is closely tied to how well conductive additives support electron transport and manage resistance within the cell.
Blended systems, such as CNTs combined with acetylene carbon blacks, are increasingly used. Orion has invested in a fully equipped battery lab to support customers in optimizing these combinations for various active systems.
Are there new standards or testing methods emerging to evaluate the performance and consistency of conductive additives in EV batteries?
AK: There is growing emphasis on the consistent quality of conductive additives. Purity requirements are stringent and must be met not only at the application level but throughout the entire manufacturing process. We’re also seeing a growing emphasis on localized supply chains. While this trend is largely driven by cost efficiency and geopolitical factors, it also simplifies material handling, reducing the risk of contamination.
MR: As EV batteries become more advanced, the way conductive additives are tested is evolving. Cell manufacturers have always evaluated carbon black throughout their own processes, but automotive programs must additionally follow strict PPAP/IATF qualification standards.
Conductive additives create a percolation network within the electrode, supporting electron transport while the active material hosts lithium ions. The interaction between structure, purity, and dispersion directly influences EV cell performance. (Check out this video to learn more.)
As a result, more automotive-grade requirements, including technical cleanliness and contamination control, are now being applied to conductive carbons, even though these materials traditionally came from a chemical industry that did not require such standards.
This shift also drives the adoption of more sensitive analytical methods to detect metallic particles and ensure consistent quality.
Filed Under: Batteries, FAQs, Featured Contributions, Q&As