Developing silicon-based anodes for lithium-ion batteries (LIBs) represents a promising pathway to significantly enhance energy storage performance. Silicon, with its high theoretical capacity, has the potential to store up to ten times more lithium ions compared to traditional graphite anodes. However, the inherent challenges associated with silicon's large volume expansions (up to 400%) during lithiation and delithiation, which lead to mechanical degradation and reduced cycle life, have hindered its widespread adoption.

This study presents the design and implementation of an innovative Chemical Vapor Deposition (CVD) process aimed at overcoming these challenges by synthesizing silicon nanostructures. The custom-built CVD system, 'Evil Octopus,' enables precise control over gas flow, temperature, and pressure, utilizing a fully automated programmable logic controller (PLC) and human-machine interface (HMI). The synthesis involves reducing silicon dioxide (SiO₂) using magnesium (Mg) at elevated temperatures, followed by a carbon deposition phase to create a protective layer. The resulting silicon nanostructures are incorporated into a porous and mechanically strong matrix, which helps mitigate the effects of volumetric expansion during battery operation.

Characterization techniques, including X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive spectroscopy (EDS), were employed to validate the morphology and phase composition of the synthesized nanostructures. The CVD system's automation capabilities provided uniform nanoparticle coatings, optimizing first-cycle efficiency and reducing first-cycle losses. This approach contributes to the advancement of next-generation lithium-ion batteries by improving energy density, essential for the widespread adoption of electric vehicles (EVs) in addressing climate challenges.

Future work will focus on scaling the CVD process for industrial applications, ensuring consistent quality and cost-effectiveness for advanced energy storage technologies. By addressing the limitations of current LIB technologies, this work aims to pave the way for more sustainable and high-performing energy solutions, which are crucial for the future of clean energy and the universal adoption of electric vehicles.