Lithium-ion cathode sheets.
Built to your spec.
LFP, NCM (111/523/622/811/9-series/90), LCO, LMO, LNMO, LRMO, SPAN — pre-coated on aluminum foil for Li-ion and Li-S research.
Every sheet made to order. Specify loading, substrate, cut size — we calibrate to your target.
Why pre-coated cathode sheets matter.
A modern lithium-ion research program starts with a chemistry decision — LFP, NCM, LCO, a high-voltage spinel, or something more exotic like Li-rich manganese or sulfurized polyacrylonitrile. The chemistry is the headline. But between the chemistry decision and a working coin cell or pouch prototype sits four to eight weeks of unglamorous work: slurry formulation, viscosity tuning, coating, drying, calendering, and quality control. For most academic labs and early-stage R&D teams, that infrastructure burden is a quiet tax on the actual science.
Pre-coated cathode electrode sheets exist to remove that tax. You specify the chemistry, the loading, the substrate, and the cut size; the sheets arrive ready to assemble. The first cell in a study can be running within a week instead of a quarter.
If you're sourcing cathode sheets for a research program, Xnergy's complete Li-ion cathode electrode sheet catalog covers all eight commercial chemistries — from LFP and the full NCM family through to LNMO, LRMO, and SPAN — with custom loading and cut specifications as the default. The four-question decision framework in § 7 walks through which chemistry fits which research goal.
How a lithium-ion cathode actually works.
A lithium-ion cell stores energy by shuttling lithium ions between two host materials through a non-aqueous electrolyte. The cathode is the high-voltage, lithium-rich host; the anode is the low-voltage host. During discharge, lithium ions migrate from the anode to the cathode, while electrons flow through the external circuit.
What defines a cathode chemistry is the crystal structure of the host material and how much lithium it can reversibly accept and release. Three structural families dominate commercial cathodes today:
- Layered oxides (LCO, NCM, NCA, LRMO) — 2D sheets of transition-metal oxides with lithium between them. High capacity, but the layered structure can collapse if too much lithium is removed. The single-crystal vs polycrystalline distinction matters most here.
- Spinel (LMO, LNMO) — a 3D framework with channels for fast lithium diffusion. Excellent rate capability; LNMO operates at an exceptional 4.7 V.
- Olivine (LFP, LMFP) — a phosphate framework with very strong P–O bonds. Lower energy density but extreme thermal and chemical stability.
A fourth class — conversion cathodes like SPAN for lithium-sulfur — sit outside the intercalation paradigm entirely and follow a different reaction mechanism (covalently bonded sulfur reducing to polysulfides).
For researchers characterizing these structures in their own lab, in-situ X-ray diffraction cells make it possible to observe lithium migration and phase transitions during cycling — complementary to ex-situ workflows documented by the U.S. National Institute of Standards and Technology.
The cathode chemistries Xnergy ships as sheets.
Iron phosphate olivine
The workhorse cathode of low-cost EVs and stationary storage. Its olivine crystal structure is exceptionally stable, doesn't release oxygen during thermal runaway, and uses no critical metals. Modern LFP cells routinely exceed 165 mAh/g — a substantial jump from the 145 mAh/g typical of LFP a decade ago.
- Capacity
- 150–165 mAh/g
- Voltage
- 3.2 V (very flat plateau)
- Used in
- Entry-level EV research, stationary storage, long-cycle benchmarking
- Risk
- Low electronic conductivity — carbon coating and additive selection matter
- Order
- LFP Cathode Sheet (Multiple Specs) · Single-Side Coated
111 / 523 / 622
The 111, 523, and 622 designations refer to the molar ratio of nickel, cobalt, and manganese in the layered oxide. As nickel content rises, so does specific capacity — but so does manufacturing sensitivity. The mid-nickel family is where most commercial Li-ion energy lived from 2015 to 2022, and it remains the default reference for benchmark studies.
- Capacity
- 155–180 mAh/g (rising with Ni content)
- Voltage
- ~3.7 V
- Used in
- Standardized benchmarking, mid-energy EV research, formulation studies
- Risk
- Voltage windows >4.3 V trigger irreversible structural transitions
- Order
- NCM111 · NCM523 · NCM622
9-series · 90 + single-crystal
The most active part of the Li-ion cathode market in 2026. As nickel content climbs toward 90%, gravimetric capacity rises into the 200–215 mAh/g range — territory previously reserved for NCA. The cost is structural: high-nickel layered oxides are sensitive to moisture, voltage overshoot, and microcrack damage during charging.
The single-crystal revolution. Polycrystalline NCM 811 is a cluster of small primary particles bonded into a larger secondary particle. During charge–discharge, these primary particles expand asymmetrically, opening microcracks at grain boundaries. New electrolyte penetrates these cracks, accelerating degradation. Single-crystal NCM 811 eliminates the grain boundaries entirely — each cathode particle is one continuous crystal. The result is roughly 2× the cycle life at the same chemistry, and the ability to push the voltage ceiling 100 mV higher without runaway capacity fade. Single-crystal high-nickel is now the de facto standard for premium EV programs (Tesla, CATL, LG).
- Capacity
- 195–215 mAh/g (NCM 811 to NCM 90)
- Voltage
- 3.7–3.8 V
- Used in
- Premium EV, high-energy aviation/UAV, single-crystal vs polycrystalline studies
- Risk
- Dry-room processing (≤1% RH) required; Li₂CO₃ forms within minutes of air exposure
- Order
- NCM811 (Poly + Single Crystal) · NCM 9-Series · NCM 90
Cobalt oxide
The original commercial lithium-ion cathode, LCO defined consumer electronics from the early 1990s through the smartphone era. It remains the highest volumetric energy density layered oxide and is preferred where volume matters more than mass — wearables, medical devices, ultra-thin laptops. As an academic reference chemistry, LCO is the cleanest benchmark for layered-oxide studies because there's only one transition metal.
- Capacity
- 140–155 mAh/g (cycled to 4.3 V)
- Voltage
- 3.8–3.9 V (highest of layered family)
- Used in
- Consumer electronics benchmarking, single-TM intercalation studies
- Risk
- Cobalt cost and supply; voltage cutoff >4.35 V degrades rapidly
- Order
- LCO Sheet (Multiple Specs) · Single/Double-Sided
Spinel family
Spinel cathodes use a 3D crystal framework instead of the 2D sheets of layered oxides. The structure offers fast lithium diffusion and excellent rate capability — but historically suffered from manganese dissolution.
LMO (LiMn₂O₄) operates at ~4.0 V and is the lowest-cost rechargeable cathode in commercial production. LNMO (LiNi₀.₅Mn₁.₅O₄) is the more strategic spinel — operating at an exceptional 4.7 V. This puts LNMO at the energy density of mid-Ni NCM with the cost structure of LMO. The bottleneck has been electrolyte stability at 4.7 V; with high-voltage electrolyte additives maturing in 2024–2026, LNMO is moving from "promising" to "deployable."
- LMO
- ~110 mAh/g · 4.0 V plateau
- LNMO ★
- ~135 mAh/g · 4.7 V plateau
- Used in
- High-power research, 4.7V electrolyte development, NCM-LMO blends
- Risk
- Standard 4.3V electrolytes fail at LNMO — pair with high-voltage formulations
- Order
- LNMO Cathode Sheet · LiMn₂O₄ Coin Cell Disc
Li-rich Mn-based
The cathode chemistry with the highest gravimetric capacity in research today — routinely 250+ mAh/g, with theoretical maxima approaching 300 mAh/g. The chemistry achieves this by activating an additional oxygen redox couple alongside the conventional transition-metal redox, dramatically increasing the lithium inventory that participates in cycling.
The trade-off is well-known: voltage fade. Each cycle progressively reduces the average discharge voltage as oxygen vacancies migrate. The 2023–2026 research push has focused on suppressing this through surface coating, doping, and biphasic intergrowth — recent reports of 200+ cycle stability with <5% voltage decay suggest the chemistry is moving from "interesting" to "practical."
- Capacity
- 250–280 mAh/g
- Voltage
- 3.5–3.8 V (with progressive fade)
- Used in
- Maximum energy density research, oxygen redox studies, advanced layered-oxide development
- Risk
- Voltage fade is real; benchmark with conservative voltage windows
- Order
- LRMO Cathode Sheet (Multiple Specs)
Sulfurized polyacrylonitrile
SPAN sits in a separate category from intercalation cathodes. It's the leading research cathode for lithium-sulfur batteries — a chemistry with theoretical energy density 5× higher than any layered oxide, but historically plagued by the polysulfide shuttle that destroys cycle life. SPAN solves the shuttle problem by covalently bonding sulfur into a polyacrylonitrile backbone, eliminating soluble polysulfide intermediates entirely.
The result is a Li-S cathode that actually cycles for 200+ cycles with 80% capacity retention — the first SPAN composites to do so reproducibly. For programs targeting Li-S commercialization, SPAN is the bridge between "interesting electrochemistry" and "deployable cell."
- Capacity
- 550–600 mAh/g (stable working capacity)
- Voltage
- 1.0–3.0 V (sloping, not flat)
- Used in
- Li-S battery research, conversion-cathode mechanism studies, high-energy aviation programs
- Risk
- Different voltage window than intercalation; requires Li-metal or alloy anode
- Order
- SPAN Cathode Electrode Sheet (Li-S)
A complete Li-ion build needs more than the cathode. Xnergy also ships Li-ion anode sheets (graphite, hard carbon, silicon-carbon), metallic lithium for half-cell reference, aluminum foil current collectors, and salts, solvents, and formulations for matched electrolyte builds.
Side-by-side comparison. 2026 data.
Representative ranges for current research and early-commercial cells. Cycle life depends strongly on voltage window, rate, temperature, and structural modification.
| Cathode | Capacity | Voltage | Cycle Life | Cost Driver | Best For |
|---|---|---|---|---|---|
| LFP | 150–165 mAh/g | 3.2 V | 4,000+ | Iron — lowest | Long-cycle, cost-driven |
| NCM 111 | 155–165 mAh/g | 3.7 V | 1,500–2,500 | Co content | Reference benchmarking |
| NCM 523 | 160–170 mAh/g | 3.7 V | 1,500–2,500 | Mid Co/Ni | Mid-Ni studies |
| NCM 622 | 170–180 mAh/g | 3.7 V | 1,200–2,000 | Rising Ni | Mid-energy programs |
| NCM 811 (poly) | 195–205 mAh/g | 3.7 V | 800–1,500 | High Ni | High-energy benchmarking |
| NCM 811 (SC) ★ | 195–205 mAh/g | 3.7 V | 1,800–3,000 | SC processing | Premium EV research |
| NCM 90 | 205–215 mAh/g | 3.7 V | 700–1,200 | 90% Ni | Max energy density |
| LCO | 140–155 mAh/g | 3.85 V | 500–1,000 | Cobalt | Consumer electronics |
| LMO | ~110 mAh/g | 4.0 V | 500–1,000 | Mn — very low | High-power, blends |
| LNMO ★ | ~135 mAh/g | 4.7 V ★ | 800–1,500 | Mn-rich | High-voltage research |
| LRMO | 250–280 mAh/g | 3.5–3.8 V | 200–500 | TM mix | Max-capacity research |
| SPAN | 550–600 mAh/g | 1.0–3.0 V | 200–400 | S + PAN | Li-S research |
Precision-sorted discs · ±0.1 mg/cm².
There's a recurring problem in coin-cell research: cell-to-cell capacity variation. You build 10 cells from the same batch of cathode material, the same anode, the same electrolyte. You cycle them. The reported capacity standard deviation is 8–12%. Is that real chemistry variation, or is it cathode mass variation?
Almost always, it's the cathode mass. Hand-cut discs from a standard sheet have a typical mass distribution of ±0.5 to ±1.0 mg/cm² — enough to swamp the signal in a careful electrochemistry study.
NCM811 Cathode Discs Ø13 mm
Precision Sorted ±0.1 mg/cm² · 50 pcs
- Tolerance
- ±0.1 mg/cm²
- Quantity
- 50 pcs
- Improvement
- 5–10× tighter
- Chemistry
- NCM811
Each disc is individually weighed and graded before packaging. The product is 5× to 10× tighter tolerance than standard pre-cut discs from any major supplier — purpose-built for mechanism studies, formulation comparison, and electrochemistry papers where the statistical claim depends on cell-to-cell reproducibility.
Custom-sorted discs in other chemistries or sizes available on request — specify chemistry, diameter, and target loading at quote.
Who needs this: mechanism studies, formulation comparison studies, electrochemistry papers where the statistical claim depends on cell-to-cell reproducibility. Half-cell rate studies, EIS measurements, and any work where capacity variance directly impacts the conclusion.
Who doesn't need this: scale-up validation, pouch cell prototyping, applications work where pouch-level variation already exceeds disc-level variation.
Built to your spec.
Every Xnergy Li-ion cathode sheet ships as a custom-built order. Three specifications you choose at the time of quote.
Active material loading
Loading determines areal capacity (mAh/cm²) and downstream cell-level performance.
- Standard research range available as catalog SKUs
- Ultra-thin loadings for rate studies
- High-load variants for pouch prototypes
- Specify target mg/cm² or target mAh/cm² at quote
Send your N/P ratio and anode pairing — our engineers will recommend a matched cathode loading.
Substrate
Aluminum foil is the standard current collector for all Li-ion cathodes.
- Standard battery-grade Al foil
- Thinner foil for high-energy research
- Thicker foil for high-load pouch builds
- Carbon-coated Al for lower contact resistance
- Single- or double-sided coating
Cut dimensions
Standard sheets ship as research-format rectangles. We also pre-cut to:
- Discs matched to CR2016 / CR2025 / CR2032
- Rectangular strips for Swagelok and pouch cells
- Custom shapes from a DXF or PDF drawing
- Research-grade tolerance
How to choose the right cathode sheet.
Walk through these four questions in order. The right answer almost always determines which downstream materials and equipment you'll also need.
What are you optimizing?
- Cycle life and cost → LFP
- Energy density at moderate cost → NCM 622 or NCM 811 (poly)
- Maximum energy density → NCM 811 single-crystal, NCM 90, or LRMO
- High-voltage research → LNMO (4.7 V plateau)
- Maximum theoretical energy → SPAN (Li-S)
- Volumetric density (small form factor) → LCO
Coin cell, pouch, or both?
Coin cell prototyping is faster and cheaper but tells you little about real cell-level performance. For coin cells, the pre-cut disc SKUs (Ø13 or Ø15 mm) cut weeks off the prep workflow. For pouch builds, full sheets are more efficient. See our coin cell assembly and pouch cell assembly equipment.
Single-crystal or polycrystalline (high-Ni NCM)?
Single-crystal is the right choice for any program planning long-cycle testing (>1,000 cycles) or pushing the voltage ceiling above 4.3 V. Polycrystalline is fine for short-cycle benchmark studies and formulation comparison. Cost differential is roughly 1.5× to 2× for single-crystal at equivalent specs.
What's your electrolyte strategy?
Most commercial liquid electrolytes are stable up to ~4.3 V. If your design pushes beyond that (LNMO at 4.7 V, high-Ni NCM at 4.4 V, LCO at 4.5 V), you need a high-voltage electrolyte system. Browse salts, solvents, and formulations, plus electrochemical testing equipment for CV and EIS validation.
For the cathode-powder side of the decision, see Lithium-Ion Battery Cathode Materials: The Complete 2026 Guide. For the sister category in sodium-ion, see Sodium-Ion Cathode Electrode Sheets: 2026 Guide.
Three trends reshaping cathodes in 2026.
Single-crystal goes mainstream.
What was premium in 2020 is now default for high-end EV programs in 2026. Single-crystal NCM 811 eliminates the grain-boundary microcracking that limits polycrystalline cycle life, with research in Joule and Nature Energy demonstrating both improved cycle life and higher voltage ceilings. Xnergy's NCM811 sheet with single-crystal option lets researchers run side-by-side polycrystalline-vs-single-crystal studies on the same coin cell or pouch platform.
Cobalt reduction becomes cobalt elimination.
The 2017–2022 era was about reducing cobalt (NCM 111 → 523 → 622 → 811). The 2024–2026 era is about eliminating it: LMFP, LNMO, and LRMO all use manganese-rich chemistries with little or no cobalt. The ReCell Center at Argonne National Laboratory has demonstrated that high-Ni regeneration and cobalt-free chemistries are converging. EU Critical Raw Materials Act mandates minimum recycled-content thresholds for cobalt, lithium, and nickel starting in 2031.
Direct cathode recycling matures.
Pyrometallurgical and hydrometallurgical recycling recover metals; direct recycling recovers the cathode material itself, dramatically reducing energy input. The ReCell Center and the Faraday Institution have demonstrated direct LFP and NCM regeneration at lab scale. As recycled cathode material enters the supply chain, materials sourced for comparative research become essential benchmarking references.
Common pitfalls working with cathodes.
Drawing from common questions we get from research customers working through Xnergy's complete cathode materials catalog:
- Calendering pressure on LFP vs NCM. LFP needs higher calendering pressure (olivine particles are harder); NCM needs lighter calendering to avoid crushing polycrystalline secondary particles. Don't apply NCM-line settings to LFP, or vice versa.
- Binder selection isn't chemistry-neutral. PVDF works for most NCM but requires careful NMP solvent handling. CMC/SBR works for LFP and is more environmentally friendly. See our binder catalog for PVDF, PTFE, CMC, and SBR.
- Conductive additive ratios aren't chemistry-neutral. NCM needs ~2% conductive carbon; LFP requires 4–5% plus an Al primer for adequate conductivity. See conductive additives.
- Slurry stability differs. NCM 811 will fall out of suspension within hours; LFP slurry is more stable but still benefits from active stirring during the coating run. See slurry mixing equipment.
- Coating uniformity matters more than peak loading. NCM 811 cells fail at the thinnest 5% of the coating, not the average. Coating uniformity (±0.5 mg/cm²) limits cycle life more than average loading does — consider calendering equipment with active feedback control.
- First-cycle irreversible capacity loss varies. NCM 811 has ~10% first-cycle loss; LFP has ~3%; LRMO has 20–25% (due to first-cycle oxygen redox activation). Build N/P from specific chemistry, not from an inherited recipe.
- Gloves come off too early. High-Ni NCM forms surface Li₂CO₃ within minutes of glove-box exit. For NCM 811 and higher, transfer to an in-situ analysis cell under inert atmosphere — a 30-min lab visit easily costs you 2% capacity at first cycle.
Frequently asked questions.
Sourcing Li-ion cathodes? Built to your spec.
A balanced research program treats the cathode as a design variable, not a stock catalog item. Specify your chemistry, loading, substrate, and cut size. We'll quote within one business day.