Tag: General Motors

Key Takeaways

1. GM’s electric trucks will standardize a range of over 400 miles on a single charge, starting with high-end versions.
2. The new manganese-rich battery (LMR) with LG will begin mass production in 2027, offering affordable 400-mile trucks by 2028.
3. LMR batteries offer better energy density and affordability compared to lithium ferrophosphate (LFP) and nickel-based batteries.
4. GM is establishing a domestic supply chain for rare-earth magnets to reduce reliance on China amid export restrictions.
5. Two rare-earth magnet manufacturing plants are set to open by year-end, supporting GM and U.S. defense needs.

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Select General Motors’ electric trucks already have high-end versions that can travel over 400 miles on a single charge, but the company is gearing up to make this standard across their entire truck range.

Exciting Battery Developments

GM has been working on a manganese-rich battery (LMR) in partnership with LG for ten years and is set to start mass production in 2027, with plans for more affordable 400-mile trucks to launch in 2028. The innovative LMR technology earned the title of “Battery Innovation of the Year” at the 2025 battery expo held in Detroit, largely due to its impressive energy density and cost-effectiveness.

Comparing Battery Technologies

The lithium-manganese battery developed by GM and LG has an energy density that surpasses that of the commonly used lithium ferrophosphate (LFP) batteries, which are found in many electric vehicles and even popular devices like Anker Prime power banks. While LFP batteries are budget-friendly and safe, they offer only average energy density. On the other hand, nickel-based batteries provide great performance and long range but are pricier and less stable because they contain metals like nickel and cobalt.

Manganese is more widely available, making the LMR battery from LG and GM more affordable than those that rely on nickel. It still offers impressive energy density that enables the creation of 400-mile trucks at a lower price and allows for 100% charging without harming battery life. Kurt Kelty, the VP of Batteries and Electrification, states:

“LMR represents the outcome of a decade of research and is a technology that will provide excellent performance at a fair price. By enhancing battery quality and controlling the supply chain, we can boost our competitiveness in North America.” GM is refining its electric vehicle range by utilizing three types of battery chemistry simultaneously: high-nickel for top performance, LFP for durability, and LMR for a good mix of performance and pricing.

Industry Insights

Elon Musk has also identified manganese technology as an ideal compromise between cost and performance, while CATL is now producing M3P manganese batteries with high energy density as well.

Sadly, American companies face challenges in accessing Chinese batteries because of tariffs and export limitations, so GM’s plan to centralize production is yielding results. Not only is its domestically developed LMP battery moving into mass production, but GM stands as the sole American car manufacturer unaffected by China’s recent restrictions on the export of rare earth mineral magnets.

These magnets play a crucial role in the electric vehicle sector, leading GM to establish a rare-earth magnet supply chain in the U.S. since 2021. They have been identifying partners and entering into long-term contracts that carry some risk. This is risky because Chinese magnets are less expensive, but with China’s ban on rare earth exports—even if they’re only for magnet production using their minerals abroad—GM’s strategy seems justified.

The company is now starting to benefit from its choice to reduce reliance on China, with two rare-earth magnet manufacturing plants expected to begin operations by the end of the year, primarily serving GM. A portion will also supply the Pentagon, which has invested $400 million in one U.S.-based magnet firm. However, the government remains a smaller client, so GM’s bet on independence in EV battery and magnet production is crucial for scaling up their operations in the U.S.

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The U.S. Department of Energy (DOE) is providing a significant loan of $670.6 million to Aspen Aerogels, a firm recognized for its fire-resistant materials designed for electric vehicle (EV) batteries. This considerable funding is aimed at finalizing Aspen’s new manufacturing plant in Georgia, where they create insulating materials specifically for EV batteries.

Tackling Battery Fires

Aspen Aerogels is addressing one of the more complicated challenges in the EV sector: the risk of battery fires. Though fires are less common compared to traditional gasoline cars, they present unique difficulties in electric vehicles because they can reignite even after being extinguished. The company’s heat-resistant materials, when integrated into battery packs, can help to slow or halt the spread of heat and flames, potentially averting catastrophic incidents.

Focusing on Safety

Jigar Shah, the leader of the DOE’s Loan Programs Office, emphasized the need to achieve the industry’s "critical battery safety goals." This funding initiative aligns with a broader effort to enhance the safety of EVs as more drivers choose these vehicles.

The primary objective of Aspen’s aerogel technology is to prevent thermal runaway, a dangerous cycle where heat and chemical reactions perpetuate one another, resulting in fires or explosions. By incorporating these thermal barriers between battery cells, automakers may contain issues to smaller sections of the battery, thereby diminishing the likelihood of a full vehicle fire.

Growing Demand

Major automotive brands like General Motors, Toyota, and Audi have already adopted Aspen’s materials in their electric vehicles. Aspen’s revenue in this sector has soared, increasing from $7 million in 2021 to an impressive $110 million by 2023, with projections indicating it could double once again in 2024.

The DOE loan will also facilitate the establishment of Aspen’s Georgia facility, with production slated to commence in early 2027. Once fully operational, the plant has the potential to supply materials for over two million EVs annually, significantly boosting the company’s manufacturing capabilities.

While these materials enhance safety, there is a slight drawback as they may reduce the energy density of batteries. However, due to the lightweight nature of aerogels, this downsides is less impactful compared to alternative solutions. Depending on how they are implemented, adding these thermal barriers could range in cost from $300 to $1,000 per vehicle.