Low-Cost Solid Electrolytes for All-Solid-State Batteries: Material Design, Scalable Manufacturing, and Perspectives on Commercialization

Commercial deployment of all-solid-state batteries depends on scalable, economically viable production of solid electrolytes. Although ASSBs offer improved safety, thermal stability, and energy density, the high cost of solid electrolytes remains a major barrier to large-scale deployment. This mini-review evaluates sulfide, oxide, polymer, and halide electrolytes through a cost-focused lens, linking material selection with synthesis conditions, energy demand, manufacturing complexity, and scalability. We examine recent industrial developments and commercialization efforts to highlight the gap between laboratory performance and economically viable production. The discussion also covers emerging opportunities in sustainable manufacturing, data-driven materials discovery, and scalable process design. By integrating materials chemistry, process engineering, and industrial perspectives, this review provides a practical framework for developing high-performance, low-cost solid electrolytes and accelerating the commercialization of ASSBs.