Penn State DuBois and Metaltech Inc. in DuBois, PA, have initiated a research project focused on next-generation energy storage, specifically targeting the development of sponge iron electrodes for iron-air batteries. Supported by a $70,000 grant from the 2025 Manufacturing PA Innovation Program, the collaboration aims to utilize mill scale, a byproduct of steelmaking, to create high-purity sponge iron electrodes. Iron-air batteries, known for their cost-effectiveness and eco-friendliness, use iron as the negative electrode and an air-based positive electrode. By converting the typically discarded mill scale into valuable sponge iron through a direct reduction process, the project not only adds value to waste but also addresses environmental challenges. The research, led by Professor Ramakrishnan Rajagopalan, involves fabricating electrodes with additives to enhance performance and lifespan. Early tests have shown promising results for the sponge iron, derived from mill scale, exhibiting redox activity crucial for energy storage applications. Metaltech Inc.'s hydrogen-based reduction process contributes to improved product quality and energy efficiency. The project, a part of the Manufacturing PA Innovation Program, emphasizes workforce development and regional innovation. The collaboration between academia and industry aims to advance iron-air battery technology for grid-scale energy storage. This joint effort not only benefits the local community but also provides students with practical experience and supports the growth of the powder metal industry.