Advances in lithium metal production technologies

Lithium metal is a critical material in advancing energy storage technologies, particularly for next-generation lithium metal batteries (LMBs). However, industrial lithium metal production relies predominantly on LiCl–KCl electrolysis. This process faces several challenges and limitations, such as the need for high-purity LiCl, low current efficiency, and the generation of chlorine (Cl 2 ) gas as a by-product. To ensure a sustainable and affordable lithium supply, recent studies have focused on improving process efficiency and developing alternative production routes. Despite this accelerating research activity, the lack of a unified and critical assessment of lithium metal production technologies hinders informed technology selection and scale-up. This review addresses this gap by examining recent advances in lithium metal production technologies, with a focus on improvements to conventional molten salt electrolysis, including feedstock optimisations, electrolyte modifications, and cell design innovations aimed at enhancing yield, purity, and energy efficiency. In addition, alternative low-temperature electrolysis enabled by aqueous-based lithium compounds, innovative electrochemical extraction methods, and thermochemical approaches using carbon and metallic reductants are summarised. The review also considers process–structure–performance relationships, highlighting how production conditions influence lithium metal microstructure and electrochemical properties. Finally, the review discusses the challenges associated with each method and highlights potential improvements to achieve more sustainable large-scale lithium metal production.