Powering the Frontline: A $1.9M Bet on U.S. Battery Independence

NORTH ANDOVER, MA – December 15, 2025 – In a move that underscores the Pentagon's growing focus on supply chain resilience, the U.S. Defense Logistics Agency (DLA) has awarded a $1.9 million grant to 6K Energy, a division of 6K Inc. While modest in dollar terms, the grant is strategically significant, targeting the domestic development of a critical component for next-generation lithium-ion batteries. The funding, part of the DLA's Battery Network (BATTNET) Program III, will accelerate the production of advanced single-crystal NMC721 cathode powders, a material essential for building safer, longer-lasting, and higher-performance batteries for military applications. This investment is not merely about a single component; it represents a calculated step in a broader national effort to onshore critical technologies and reduce America's precarious dependence on foreign supply chains for its defense and energy security.

The Pentagon's Pivot to Supply Chain Sovereignty

The DLA's BATTNET program is a core element of the Defense Manufacturing Technology (ManTech) Program, designed specifically to address vulnerabilities in the military's power sources. Its objectives are clear: strengthen the domestic battery supply chain, improve safety and shelf life, and ensure that warfighters have reliable power in increasingly contested environments. For years, the Department of Defense has recognized that over-reliance on foreign nations, particularly geopolitical rivals, for essential materials like cathode powders creates an unacceptable strategic risk. This grant to 6K Energy directly confronts that risk.

By funding the development of single-crystal (SC) NMC721, the DLA is investing in a material chemistry particularly suited for the demanding requirements of military hardware. The program aligns with the DLA's strategic plan to transform its capabilities and build more resilient supply solutions, moving away from fragile, just-in-time global logistics toward a more robust domestic industrial base. The 12-month program will see 6K Energy scale up its synthesis process, optimize the material, and conduct rigorous performance validation, including full-cell testing in collaboration with a U.S.-based lithium-ion cell manufacturer. This end-to-end domestic approach—from powder synthesis to cell testing—is precisely the kind of ecosystem the U.S. government aims to foster under initiatives like Executive Order 14017 on America's Supply Chains.

"This award recognizes the capabilities of our UniMelt platform and validates our ability to produce NMC721 domestically and sustainably," said Dr. Saurabh Ullal, CEO of 6K Inc. and President of 6K Energy. "We appreciate the confidence that the DLA and the BATTNET program have placed in 6K Energy, and we believe this effort will accelerate the delivery of high-performance NMC721 materials critical to our nation's defense and energy security."

A Technological Leap in Sustainable Manufacturing

At the heart of this strategic initiative is 6K's proprietary UniMelt® microwave plasma technology. This platform represents a fundamental departure from the conventional, energy-intensive, and waste-heavy methods traditionally used to produce cathode active materials (CAM). The conventional co-precipitation route requires long, multi-day heating cycles in massive furnaces, uses flux additives, and generates significant chemical waste and wastewater. In stark contrast, the UniMelt process uses a high-energy microwave plasma to convert input materials into high-performance powders in a matter of seconds.

This radical efficiency has profound implications for both cost and sustainability. According to a Life Cycle Assessment (LCA) conducted by the independent firm Minviro, Ltd., the UniMelt approach can slash energy consumption and processing costs by up to 50% compared to traditional production. Furthermore, a separate Department of Energy assessment for 6K's planned larger-scale PlusCAM™ facility in Tennessee noted the process could reduce greenhouse gas emissions by 70% and water usage by 90% while generating zero hazardous waste. This combination of economic and environmental benefits positions UniMelt as a disruptive force, offering a pathway to ultra-sustainable, low-cost domestic CAM production.

"Our single-crystal NMC811 and other high-nickel NMC materials have been sampled widely by OEMs and cell manufacturers with outstanding results," stated Dr. Richard Holman, CTO of 6K Energy. "This BATTNET award gives us the opportunity to push the boundaries for NMC721 and again demonstrate that our UniMelt technology can deliver highly sought-after, high-quality battery materials at scale right here in the United States."

The Science of Superior Performance: Single-Crystal Cathodes

The focus on single-crystal NMC721 is not arbitrary; it is driven by the need for superior battery performance and durability. Most conventional cathodes are polycrystalline, meaning they are composed of many smaller crystal grains clumped together. Under the stress of repeated charging and discharging, especially at higher voltages, cracks can form and propagate along these grain boundaries. This microcracking exposes more of the material to the battery's electrolyte, leading to unwanted side reactions, gas generation, and a rapid decline in performance and cycle life—a critical failure point for military equipment.

Single-crystal cathodes, as their name implies, are each composed of a single, continuous crystal lattice. Lacking the vulnerable grain boundaries of their polycrystalline counterparts, they are far more resistant to mechanical stress and cracking. This structural integrity results in significantly enhanced cycling stability and improved thermal safety, as the reduced surface area minimizes undesirable reactions with the electrolyte. The result is a battery that lasts longer, performs more reliably, and is inherently safer, all crucial attributes for defense applications. 6K's UniMelt process is uniquely suited to producing these advanced structures, overcoming the high-temperature, long-duration challenges that make single-crystal production difficult and expensive with conventional methods.

This DLA grant, therefore, is not just funding production but is catalyzing the adoption of a superior material science platform. By enabling the scaled domestic production of SC NMC721, the program is helping to ensure that the U.S. military's next generation of powered equipment benefits from the highest levels of performance and reliability, directly contributing to mission readiness and warfighter safety.