A recent report from IDTechEx offers a path to PFAS-free lithium-ion batteries

As global regulators tighten restrictions on per- and polyfluoroalkyl substances (PFAS) — the so-called “forever chemicals” — the battery industry faces growing pressure to eliminate these persistent compounds from lithium-ion cell manufacturing

A new report from IDTechEx, ‘Additives for Li-ion Batteries and PFAS-Free Batteries 2026–2036: Technologies, Players, Forecasts’, outlines how novel polymer systems and electrolyte additives are emerging as viable replacements for PFAS, signalling the beginning of a new era in sustainable battery chemistry.

PERFORMANCE AT AN ENVIRONMENTAL COST

PFAS encompass a vast family of over 5,000 fluorinated compounds known for their chemical stability, thermal resistance, and non-stick properties. These same characteristics have made them invaluable to modern energy storage systems, where stability and adhesion are critical for cell longevity and safety.

In lithium-ion batteries, PFAS materials serve multiple roles. The most widespread use is as binders in electrode formulations. Polyvinylidene fluoride (PVDF), a PFAS-based polymer, dominates cathode binder systems due to its strong adhesion to active materials and conductive additives, as well as its electrochemical inertness. On the anode side, however, many manufacturers have already shifted toward water-based, non-fluorinated binders such as carboxymethyl cellulose (CMC) and styrene-butadiene rubber (SBR).

As manufacturing transitions toward dry electrode processing, where solvent-free coating methods reduce energy consumption and waste, PVDF is increasingly being replaced with polytetrafluoroethylene (PTFE) – another fluoropolymer in the PFAS family. In electrolytes, PFAS-based compounds also appear as functional additives, including fluorinated lithium salts, flame retardants, and co-solvents such as hydrofluoroethers, all designed to enhance conductivity, interfacial stability, and safety.

Despite these benefits, PFAS materials are now facing unprecedented scrutiny due to their persistence in the environment, bioaccumulative properties, and links to health concerns such as cancer and developmental effects. With the European Union, the US Environmental Protection Agency, and other bodies proposing strict limitations or outright bans on PFAS use, the battery sector is rapidly exploring ways to replace these materials without compromising cell performance.

THE SEARCH FOR VIABLE ALTERNATIVES

According to IDTechEx, the path toward PFAS-free batteries requires coordinated innovation across both binder and electrolyte additive domains.

Replacing PFAS-based binders like PVDF and PTFE demands materials that maintain strong particle adhesion, chemical resistance, and mechanical flexibility under high-voltage conditions. Several promising candidates have emerged. Polyacrylic acid (PAA) and polyethylene oxide (PEO) are among the most advanced non-fluorinated binders currently being evaluated. PAA, a water-soluble polymer, offers strong adhesion and good compatibility with aqueous electrode processing, reducing the need for toxic solvents such as NMP (N-methyl-2-pyrrolidone). PEO, meanwhile, provides ionic conductivity and flexibility, attributes valuable for both electrodes and solid-state electrolyte interfaces.

Some manufacturers are already implementing PFAS-free solutions. Leclanché, for instance, has publicly announced the removal of PFAS from its binder systems. Meanwhile, innovators such as Nanoramic Laboratories and 24M Technologies are developing binder-free electrode architectures that eliminate polymeric binders altogether, simplifying the electrode structure while improving recyclability and throughput.

Electrolyte additives represent another significant PFAS use case. Traditionally, fluorinated compounds have been used to stabilie the solid-electrolyte interphase (SEI) and suppress gas generation under high voltage or temperature stress. Moving away from these requires careful reformulation to preserve safety and stability.

IDTechEx identifies several commercially viable non-fluorinated additives already in use. Lithium bis(oxalato)borate (LiBOB) is gaining traction as an SEI-forming additive that improves cycle life and high-temperature performance without relying on PFAS. Vinylene carbonate (VC) is another well-established additive, enhancing SEI stability and protecting the anode surface in conventional and high-energy chemistries alike.

More recently, electrolyte specialists such as E-Lyte Innovations have announced PFAS-free electrolyte formulations, demonstrating that functional replacements can meet stringent performance criteria. However, as IDTechEx notes, PFAS remediation is not simply a matter of one-to-one substitution. Electrolyte formulations are complex, and replacing a single additive can alter multiple interdependent parameters, including ionic conductivity, viscosity, and SEI composition. This makes collaborative R&D between material suppliers, cell manufacturers, and OEMs essential.

REGULATORY DRIVERS

The transition toward PFAS-free batteries comes at a pivotal time for the transport and energy storage industries. With lithium-ion technologies underpinning the global shift to electric mobility and renewable energy integration, regulatory compliance is becoming a key differentiator for suppliers.

IDTechEx forecasts that the market for non-PFAS battery additives will surpass $2 billion by 2036, as both environmental policy and supply chain sustainability drive demand for safer, more circular chemistries. Europe is expected to lead adoption due to proactive regulation and strong public concern, followed by North America and East Asia as local laws and OEM sustainability mandates align.

Material qualification timelines and manufacturing validation remain major challenges. Developing new binders or additives is not only a matter of chemistry – it requires comprehensive testing across the entire battery lifecycle, from slurry mixing to recycling. Compatibility with established electrode fabrication processes and the cost of retooling are key barriers to rapid implementation.

Despite these hurdles, momentum toward PFAS elimination is clearly accelerating. “Forever chemicals” are becoming increasingly untenable in an industry built on the promise of clean technology. Through a combination of polymer innovation, additive reformulation, and next-generation electrode design, the sector is making measurable progress toward sustainable, PFAS-free batteries.