The global transition toward efficient, sustainable, and cost-effective energy storage is accelerating, driven by efforts to decarbonize key sectors. Among emerging technologies, sulfur-based conversion cathodes have garnered significant attention as promising candidates for next-generation batteries due to their exceptional theoretical energy density, low cost, and material abundance. Their successful deployment could advance critical applications, including electric mobility, renewable energy integration, and grid stabilization. Despite this potential, sulfur cathodes face persistent limitations that have prevented commercialization. Unlike reviews focusing primarily on materials innovations in idealized settings, this work provides a critical, user-focused assessment that prioritizes challenges of scalable manufacturing and operation under practical conditions. We analyze fundamental failure mechanisms under realistic parameters, including high sulfur loading, lean electrolyte, and limited lithium anode excess, that cause performance to diverge dramatically from target metrics. By synthesizing recent advancements in mechanistic understanding, host design, and interface engineering, we identify key bottlenecks hindering large-scale production. The review concludes with strategic pathways spanning materials design, device architecture, and market integration to bridge the gap between laboratory research and real-world application. The global shift towards sustainable energy storage highlights sulfur-based conversion cathodes as promising candidates for next-generation batteries, yet commercialization remains elusive due to persistent limitations. In this Review, the authors critically assess challenges in scalable manufacturing and operation, identifying key bottlenecks and proposing strategic pathways to bridge laboratory research with real-world applications.
Manzini et al. (Fri,) studied this question.