Li-ion battery-based energy storage is widely regarded as the best technology to realize affordable electrification of the transportation sector, including xEVs and heavy-duty applications including buses, shipping, mining, and agriculture. In order to meet the growing demand and sustainably compete in this rapidly expanding industry, Li-ion cell manufacturers like XALT Energy must overcome several significant R&D and manufacturing challenges. First, these applications require both high energy density and long lifetime, and it is difficult to avoid direct tradeoffs between the two with strategies for higher energy such as higher voltage charging, higher-Ni cathodes like NCM-811, and thicker electrodes. Second, cell manufacturers must predict and replicate numerous performance metrics of commercial-scale cells from small-scale test vehicles, such as coin cells and single-layer pouch cells. Third, the cell lifetimes required in these applications are 1,000’s of cycles and 10’s of years at 25°C, much longer than commercial development cycles, requiring the use of “accelerated” testing with a high level of confidence. All the above represent significant barriers to the adoption of potentially valuable academic breakthroughs and advanced manufacturing. We will discuss how XALT Energy approaches these problems in the context of commercializing a Ni-rich cathode-based “Gen 2” 63 Ah product, and share our perspective of what kinds of advanced manufacturing are of greatest interest to lower cell cost, raise energy/power density, and extend lifetime.