4th State Energies produces advanced silicon powders using a low-energy plasma process to fully replace graphite in lithium-ion batteries. The materials are chemistry- and format-agnostic, drop-in compatible, and third-party validated, enabling U.S.-based production of high-energy, low-cost anodes for electric vehicles, drones, and next-generation portable devices.
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Pankaj Ghildiyal
Pankaj Ghildiyal is the co-founder and CTO of 4th State Energies, which develops plasma-created silicon to power next-generation lithium-ion batteries. Originally from the Indian Himalayas, he earned a Ph.D. in chemistry from the University of Maryland, focusing on gas-phase synthesis of nanostructured materials for energy applications. He now applies this expertise to advance high-performance, scalable battery materials. His work has been featured in Wired and The Wall Street Journal and supported by federal innovation grants.
TECHNOLOGY
Critical Need
The future of energy storage relies on continued innovation in electrode materials. Graphite—the dominant anode material in lithium-ion batteries—is a critical mineral strained by global demand, supply chain risks, energy-intensive production, and limited capacity. While silicon offers far greater energy density and is more earth-abundant, its commercialization has been constrained by high cost, swelling issues, and poor compatibility with existing manufacturing lines. There is an urgent need for a scalable, low-cost silicon solution that integrates into current battery production methods and enables higher-capacity, longer-lasting batteries without requiring changes to existing infrastructure.
Technology Vision
4th State Energies uses a proprietary plasma process to produce sub-10 nanometer silicon powders for lithium-ion anodes. Their small size inherently stabilizes silicon while remaining compatible with roll-to-roll manufacturing. The materials work with any battery chemistry or format, and their properties, including porosity and surface chemistry, can be tailored for specific applications. The plasma process operates at room temperature and converts raw materials into silicon within milliseconds, enabling high throughput and low energy costs. Closely related to semiconductor fabrication methods, this process scales efficiently by leveraging existing U.S. infrastructure and expertise, enabling scalable domestic manufacturing of next-generation energy storage materials.
Potential for Impact
By replacing graphite with plasma-created silicon, 4th State Energies enables higher energy density, longer runtime, and faster charging in applications such as drones, electric vehicles, and portable electronics. Its drop-in compatibility lets manufacturers adopt silicon anodes without modifying existing lines, and the technology works across battery chemistries and formats. At scale, it supports U.S.-based production of low-cost, high-performance anode materials through a clean, energy-efficient process. This platform enables application-specific tuning, reduces dependence on imported graphite, and strengthens the domestic battery supply chain.
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4th State Energies