1 EXECUTIVE SUMMARY
1.1 Why PFAS-free batteries, and why now
1.2 Key findings
1.3 The regulatory timeline at a glance
1.4 Global market forecasts, 2026-2036
1.5 Strategic implications
1.5.1 For battery cell manufacturers
1.5.2 For materials suppliers
1.5.3 For automakers and energy-storage integrators
2 PFAS IN BATTERIES: WHERE, WHY AND HOW MUCH
2.1 Definition and classification
2.2 PFAS-bearing components of a lithium-ion cell
2.3 Why PFAS have been hard to replace
2.4 Health and environmental concerns
2.5 Quantifying the PFAS footprint of the global battery industry
3 THE REGULATORYLANDSCAPE, 2023-2030
3.1 European Union: REACH universal PFAS restriction
3.1.1 Procedural timeline
3.1.2 RAC and SEAC positions
3.1.3 Likely derogations for batteries
3.1.4 Interaction with the EU Batteries Regulation (2023/1542)
3.2 United States
3.2.1 Federal: TSCA Section 8(a)(7)
3.2.2 State actions
3.3 China
3.4 Japan and South Korea
3.5 Other jurisdictions
3.6 Voluntary and procurement-driven phase-outs
4 PFAS-FREE BINDERS
4.1 Function and requirements of a battery binder
4.2 PVDF and its variants: the incumbent
4.3 Anode binders: largely already PFAS-free
4.4 Cathode binder alternatives
4.4.1 Acrylate-based aqueous binders (SA, PAA, PAA-Li)
4.4.2 Aromatic polyamide (aramid) binders
4.4.3 Bio-based polymers: lignin, alginate, cellulose derivatives
4.4.4 Thermoplastic elastomers
4.4.5 Dry-process PFAS-free binders
4.5 Performance comparison
4.6 SWOT - PFAS-free cathode binders
4.7 PFAS-free cathode binder market forecast
5 PFAS-FREE EELCTROLYTES
5.1 The electrolyte system: salt, solvent, additives
5.2 The lithium salt
5.2.1 LiPF6: the incumbent (and its regulatory status)
5.2.2 LiFSI and LiTFSI: fluorinated sulfonimide salts
5.2.3 Fluorine-free salts
5.3 PFAS-bearing solvents and additives
5.4 Solid and semi-solid electrolytes as a PFAS-free path
5.5 SWOT - PFAS-free electrolytes
5.6 Market forecast: PFAS-free electrolyte salts and additives
6 PFAS-FREE SEPARATORS
6.1 Separator basics
6.2 Ceramic-coated separators and PVDF binders
6.3 Aramid and non-woven alternatives
7 CURRENT COLLECTOR COATINGS, SEALANTS AND PACK MATERIALS
7.1 Aluminium and copper current-collector coatings
7.1.1 Function and incumbent chemistry
7.1.2 PFAS-free coating chemistries
7.1.3 Suppliers of carbon-coated current-collector foils
7.1.4 Strategic importance of carbon-coated foil supply
7.2 Tab welds, gaskets and hermetic seals
7.2.1 Function
7.2.2 Incumbent PFAS materials
7.2.3 PFAS-free alternatives
7.2.4 Suppliers of PFAS-free sealants and gaskets
7.2.5 Tab-weld interface materials
7.3 Pouch laminates and prismatic can liners
7.3.1 Pouch cell laminate construction
7.3.2 Major pouch laminate suppliers
7.4 Targray - distribution of multiple pouch film grades
7.4.1 Prismatic and cylindrical can liners
7.5 Pack-level structural materials
7.5.1 Structural adhesives and bonding
7.5.2 Dielectric and electrical-insulation coatings
7.5.3 Thermal interface materials (TIMs)
7.5.4 Vibration damping and structural foams
7.5.5 Cell-to-cell isolation pads (compressible thermal-runaway barriers)
7.6 Pack material substitution summary
7.7 Strategic implications
8 PFAS-FREE BATTERY-PACK FIRE PROTECTION
8.1 Why fire protection is the largest near-term PFAS-free opportunity
8.2 The thermal-runaway protection challenge
8.2.1 What pack fire protection has to do
8.2.2 Why fluorochemistry was historically the default
8.2.3 The substitution paradox
8.3 Three sub-segment families
8.3.1 Intumescent coatings
8.3.2 Ceramic and aerogel thermal barriers
8.3.3 Cell-to-cell isolation pads
8.4 Market forecast and competitive landscape
8.5 Application and platform dynamics
8.5.1 EV battery packs
8.5.2 Commercial vehicles, buses, heavy-duty trucks
8.5.3 Grid-scale stationary storage
8.5.4 Consumer electronics
8.5.5 Defence and aerospace
8.6 Supplier landscape and competitive positioning
8.7 Strategic implications
9 MANUFACTURING PROCESS IMPLICATIONS
9.1 The end of NMP
9.1.1 NMP's role in conventional Li-ion manufacturing
9.1.2 What aqueous slurry processing eliminates
9.1.3 The brownfield-greenfield asymmetry
9.2 Aqueous slurry process changes
9.2.1 Carbon-coated aluminium foil
9.2.2 Surface treatment of cathode active material
9.2.3 Rheology, viscosity and mixing
9.2.4 Drying-oven profiles
9.2.5 Calendering and porosity
9.2.6 The cumulative qualification cost
9.3 Dry electrode processes
9.3.1 Why PTFE is hard to replace
9.3.2 The three architectural alternatives
9.3.3 Other dry-process equipment suppliers
9.3.4 The strategic dilemma for cell makers
9.4 The three competing manufacturing routes
9.5 Capex and opex implications
9.6 Quality control and process analytical technology
9.7 Process equipment vendors and the manufacturing ecosystem
9.8 Manufacturing-readiness summary by application
9.9 Strategic implications
10 PFAS CONSIDERATIONS BY BATTERY CHEMISTRY
10.1 LFP (lithium iron phosphate)
10.1.1 Why LFP is the easiest
10.1.2 Energy density and cost trajectory under PFAS substitution
10.1.3 Chinese LFP capacity and the structural PFAS-free position
10.1.4 European, US and Indian LFP capacity build-out
10.1.5 LMFP and the energy-density gap to NMC
10.1.6 Cell formats and integration architectures
10.1.7 LFP/LMFP recycling and end-of-life PFAS implications
10.1.8 LFP substitution timeline
10.2 NMC and NCA (nickel-rich layered oxides)
10.2.1 The compounding substitution challenge
10.2.2 NMC sub-chemistry detail
10.2.3 Cathode active material supply chain and surface treatments
10.2.4 Korean cell maker positioning in detail
10.2.5 European premium NMC players
10.2.6 Tesla 4680 and the dry-process question
10.2.7 Other major NMC/NCA cell makers
10.2.8 NMC cost trajectory under PFAS substitution
10.2.9 NMC timeline
10.3 LCO (lithium cobalt oxide) and other consumer-electronics chemistries
10.3.1 LCO and consumer-cell players
10.3.2 Specialty consumer chemistries
10.4 Sodium-ion batteries
10.4.1 Three Na-ion cathode families in detail
10.4.2 Hard carbon anode supply chain
10.4.3 Sodium-ion electrolytes
10.4.4 Chinese Na-ion cell makers
10.4.5 Western, Indian and other Na-ion players
10.4.6 Na-ion market trajectory
10.5 Solid-state batteries
10.5.1 Three solid electrolyte families
10.5.2 Cell maker landscape - sulfide-based
10.5.3 Cell maker landscape - oxide-based
10.5.4 Polymer-electrolyte and hybrid
10.5.5 Lithium-metal anode programmes
10.5.6 ASB substitution timeline
10.5.7 Li-S players
10.6 Redox flow batteries
10.6.1 Membrane alternatives
10.6.2 Vanadium flow players
10.7 Lead-acid, NiMH and primary cells
11 APPLICATIONS
11.1 The application landscape, 2036
11.2 Passenger battery electric vehicles
11.2.1 Demand structure
11.2.2 What's driving PFAS-free conversion in BEVs
11.2.3 The cell supply structure
11.2.4 Forecast
11.3 Commercial vehicles, buses and trucks
11.3.1 Demand structure
11.3.2 What's driving PFAS-free conversion in commercial vehicles
11.3.3 Forecast
11.4 Grid-scale stationary energy storage
11.4.1 Demand structure
11.4.2 What's driving PFAS-free conversion in grid storage
11.4.3 System integrators and project developers
11.4.4 Forecast
11.5 Behind-the-meter storage (commercial, industrial, residential)
11.5.1 Demand structure
11.5.2 What's driving conversion
11.5.3 Forecast
11.6 Consumer electronics
11.6.1 Demand structure
11.6.2 What's driving conversion
11.6.3 Forecast
11.7 Industrial, marine, aviation and defence
11.7.1 Demand structure
11.7.2 Notable players
11.7.3 Forecast
11.8 Cross-application synthesis
12 GLOBAL MARKET FORECASTS 2026-2036
12.1 Methodology
12.1.1 Scenario definitions
12.2 Three-scenario total PFAS-free battery materials forecast
12.3 Forecast by region, 2036 (Base scenario)
12.3.1 Regional dynamics
12.4 PFAS-free Li-ion cell production forecast (GWh)
13 COMPETITIVE LANDSCAPE
13.1 Materials suppliers - landscape overview
13.2 Strategic positioning matrix
13.3 Cell makers - public PFAS-free positions
13.4 Strategic positioning matrix visualisation
14 RISKS, BOTTLENECKS AND OPEN QUESTIONS
14.1 Regulatory risks
14.2 Technical risks
14.3 Commercial and supply-chain risks
14.4 Key open questions
16 RESEARCH METHODOLOGY
16.1 Scope and approach
16.2 Data sources and validation
16.3 Forecast model architecture
16.4 Limitations
LIST OF TABLES
Table 1. PFAS-free battery materials market by segment, 2026-2036 (US$ billion, Base scenario)
Table 2. PFAS-free Li-ion cell production, 2026-2036 (GWh, Base scenario)
Table 3. PFAS-free battery materials demand by end application, 2036 (US$ billion, Base scenario)
Table 4. Typical PFAS content of a representative 75 kWh NMC811 EV cell pack
Table 5. Estimated PFAS use in Li-ion battery production, 2025-2036 (kilotonnes)
Table 6. Indicative regulatory deadlines for PFAS in batteries (Base scenario)
Table 7. Selected PFAS-free cathode binder performance vs PVDF benchmark
Table 8. Global PFAS-free cathode binder demand and value, 2026-2036 (Base scenario)
Table 9. Global PFAS-free electrolyte materials demand, 2026-2036 (US$ million, Base scenario)
Table 10. PFAS exposure and substitution status by pack-material category
Table 11. PFAS-free pack fire-protection coatings market, 2026-2036 (US$ billion, Base scenario)
Table 12. PFAS-free pack fire-protection suppliers
Table 13. Indicative gigafactory cost differential, PVDF/NMP vs PFAS-free aqueous (per GWh of capacity)
Table 14. PFAS-free manufacturing-readiness by application and 2026 status
Table 15. PFAS-free battery materials demand by application, 2026-2036 (US$ billion, Base scenario)
Table 16. PFAS-free battery materials market under three scenarios, 2026-2036 (US$ billion)
Table 17. PFAS-free battery materials value by region, 2036 (US$ billion, Base scenario)
Table 18. PFAS-free Li-ion cell production, 2026-2036 (GWh, Base scenario)
Table 19. Strategic positioning of materials suppliers
Table 20. Cell makers and their public PFAS positions
LIST OF FIGURES
Figure 1. Where PFAS lives in a typical Li-ion EV battery cell
Figure 2. PFAS regulatory timeline, 2023-2042
Figure 3. PFAS-free battery materials market by segment, 2026-2036
Figure 4. PFAS mass distribution in a 75 kWh NMC811 EV pack (kg, mid-range estimate)
Figure 5. Annual PFAS use in Li-ion battery production, 2025-2036 (kilotonnes)
Figure 6. RAC versus SEAC positions on PFAS in batteries
Figure 7. PFAS-free cathode binder chemistry landscape
Figure 8. Voltage stability vs commercial maturity for PFAS-free cathode binders
Figure 9. SWOT - PFAS-free cathode binders
Figure 10. PFAS-free cathode binder consumption and market value, 2026-2036
Figure 11. Lithium electrolyte salt landscape by PFAS status
Figure 12. SWOT - PFAS-free electrolytes
Figure 13. PFAS-free electrolyte materials market, 2026-2036
Figure 14. PFAS-free separator substitution paths
Figure 15. Pack fire protection: the fastest-growing PFAS-free segment
Figure 16. PFAS-free pack fire-protection market by sub-segment, 2026-2036
Figure 17. Three cathode manufacturing routes and their PFAS exposure
Figure 18. Gigafactory capex differential at 50 GWh scale (US$ million, one-off)
Figure 19. PFAS substitution difficulty matrix by chemistry
Figure 20. PFAS-free battery materials demand by application, 2026-2036
Figure 21. PFAS-free battery materials demand by application, 2036
Figure 22. Three-scenario PFAS-free battery materials forecast, 2026-2036
Figure 23. PFAS-free battery materials demand by region, 2036
Figure 24. PFAS-free Li-ion cell production trajectory, 2026-2036
Figure 25. Materials supplier strategic positioning matrix
Figure 26. All-polymer battery schematic.
Figure 27. All Polymer Battery Module.
Figure 28. Resin current collector.
Figure 29. Ateios thin-film, printed battery.
Figure 30. Blue Solutions module.
Figure 31. Gelion Endure battery.
Figure 32. Schematic of Ion Storage Systems solid-state battery structure.
Figure 33. Lyten batteries.
Figure 34. Prieto Foam-Based 3D Battery.
Figure 35. ProLogium solid-state battery.
Figure 36. SES Apollo batteries.
Figure 37. Solid Power battery pouch cell.
Figure 38. Stora Enso lignin battery materials.
Figure 39. Zeta Energy 20 Ah cell.
