Aerospace and Defense: Scaling High-Performance Battery Electrode Coatings with a Secure U.S. Supply Chain

In aerospace and defense systems, reliable battery performance is mission critical. Battery electrode coating plays a central role in maintaining the energy density, consistency, and durability these applications require. 

From unmanned aerial systems (UAS), drones, and military communications equipment to satellites and next-generation aircraft, batteries must deliver exceptional energy density, consistent performance, and uncompromising reliability under extreme conditions. As government agencies and defense contractors continue to prioritize domestic sourcing, manufacturers face increasing pressure to build a resilient aerospace battery supply chain supported by secure U.S. battery manufacturing for critical battery components. 

One of the most important—and often overlooked—components in defense battery manufacturing is the battery electrode coating process.

Battery performance begins with the precision coating of anodes, cathodes, and current collector foils. 

Even minor variations in coating thickness, porosity, loading density, or adhesion can impact: 

• Cycle life
• Power output
• Energy density
• Thermal stability
• Reliability in harsh operating environments 

For aerospace and military applications, these variables directly affect mission readiness and system performance. 

Kodak applies more than a century of expertise in precision roll-to-roll coating to manufacture battery prime foils and electrodes with exceptional consistency and quality control. Kodak's advanced coating operations support slot die, gravure, and flexographic coating, multilayer coating architectures, in-line quality monitoring, slitting and calendaring, and aqueous and solvent-based formulations. This enables aerospace and defense developers to move rapidly from concept validation to production-scale battery electrode coating without changing suppliers.

Choosing a coating partner is not just about available capacity. Developers need a supplier that can support technical requirements, protect sensitive materials, and scale from pilot work to commercial production without adding unnecessary qualification risk. 

• Repeatable coating performance from pilot trials through commercial volumes
• Experience with multiple chemistries, substrates, current collectors, and separator materials
• Compatibility with aqueous and solvent-based formulations
• In-line quality monitoring to detect coating defects, thickness variation, and web handling issues early
• Integrated slitting, calendaring, and downstream handling to reduce handoffs and streamline qualification
• Domestic production capabilities that support supply chain security, confidentiality, and program continuity
• A clear scale-up pathway that minimizes supplier changes and reduces technical risk

For aerospace and defense battery programs, domestic production can be an important sourcing consideration. A U.S.-based coating partner can help programs align development and production within a domestic manufacturing footprint. 

Kodak offers an established domestic manufacturing footprint backed by extensive experience coating advanced battery materials. With over a decade of battery-related manufacturing experience, Kodak has produced battery foils, electrodes, and energy-related materials for customers ranging from technology startups to large-scale enterprise programs—supporting secure U.S. battery manufacturing needs across advanced energy, aerospace, and military battery technology applications.

Kodak has successfully helped customers scale electrode, prime foils, and other battery  components from conceptual development through commercial production, including supporting a large electric vehicle program that transitioned from development-scale coating to high-volume manufacturing. This proven scale-up experience helps aerospace and defense innovators move from early battery electrode coating trials to reliable production for demanding defense battery manufacturing programs.

Whether developing lithium-ion batteries, lithium-sulfur technologies, solid-state batteries, or specialized military power systems, manufacturers need a partner capable of scaling innovation. 

Kodak provides a seamless transition from development to commercial production, helping accelerate qualification programs, reduce manufacturing risk, and shorten time to deployment for specialized aerospace platforms, drones, and military battery technology applications.

For aerospace and defense battery developers, the path from promising material to qualified production depends on precision, repeatability, and a secure scale-up strategy. Kodak brings proven roll-to-roll coating expertise, integrated manufacturing capabilities, and a U.S.-based production footprint to help reduce risk at every stage of development. If your program is moving from concept validation to pilot trials or preparing for commercial-scale production, Kodak can help you evaluate the right coating approach and build a practical pathway to scale.

Contact Kodak to discuss your battery coating requirements and explore how our team can support your next stage of development.