Materials- and Process-Driven Microstructural Engineering for Scalable Dry-Processed Electrode Manufacturing

Abstract

Solvent-free dry-processed electrode (DPE) technology has emerged as a promising platform for lithium-ion battery (LIB) manufacturing, offering a low carbon footprint, enhanced energy efficiency, and cost-effectiveness compared to conventional slurry-based processes. In addition to its process sustainability, the dry process enables a distinctive electrode microstructure—characterized by a well-interconnected pore network, low tortuosity, broadened active surface area, and improved electron conduction pathways—that can support both higher energy density and power performance. Although significant progress has been made at the laboratory scale, several critical challenges—such as non-uniform binder distribution, insufficient mechanical integrity during large-scale manufacturing, and limitations in current collector compatibility—continue to hinder the commercialization of DPEs while preserving their microstructural advantages. Overcoming these barriers requires synergistic innovations in both materials design and process engineering. This review highlights recent advancements in key material components—including active materials, conductive additives, binders, and current collectors—as well as process technologies such as powder mixing, kneading, laminating, and calendering, all from the perspective of microstructural optimization. We discuss how material innovations can address process limitations, and conversely, how novel process strategies can accommodate material constraints. Finally, this review provides a microstructure-centric perspective on materials and process innovations that are essential for enabling the scalable production of high-performance and sustainable DPEs with unique microstructural features.