Dry Electrode Fabrication for Lithium-Ion and Next-Generation Batteries: Materials, Processing, and Electrochemical Performance

Dry electrode fabrication is emerging as a transformative approach to the manufacture of lithium-ion and next-generation battery cells. By eliminating solvent-based slurry casting, this process can reduce energy consumption, avoid the use and recovery of toxic solvents such as N-methyl-2-pyrrolidone, and enable thicker electrodes with higher active-material loading and improved cell-level energy density.The adoption of dry cathode processing in large-format cells, together with growing industrial interest in solvent-free production lines, has accelerated the transition of dry electrode manufacturing from a laboratory concept to a near-term technological priority. Nevertheless, important materials and processing challenges remain. The mechanisms of binder fibrillation, the formation of conductive and porous electrode networks, and the relationships between dry-processing conditions, microstructure, mechanical integrity, ionic transport, and electrochemical performance are not yet fully understood. Further investigation is also needed to establish how dry processing can be adapted to next generation battery system deploying lithium metal anode or solid-state electrolyte.This Research Topic aims to advance the fundamental understanding and practical development of dry electrode fabrication for lithium-ion and next-generation battery cells. It will bring together research on solvent-free binders, powder processing, electrode formation, structural characterization, electrochemical evaluation, and manufacturing scale-up. Particular attention will be given to establishing processing—structure—property relationships and to comparing dry—and wet—processed electrodes under equivalent testing conditions.The Research Topic will also examine strategies for achieving high mass loading, uniform carbon-binder domain distribution, robust adhesion, and efficient ionic and electronic transport for reaction homogeneity. Contributions addressing manufacturing readiness, environmental performance, cost reduction, and the integration of dry processing into large-scale battery production are especially encouraged. Recent advances in fibrous binder architectures (for example, dual-fibrous PTFE structures for uniform, thick dry electrodes) further highlight the relevance and timeliness of this research area.This collection focuses on the dry binder materials, processing, characterization, performance, and scale-up of solvent-free electrodes for lithium-ion and next-generation battery cells, while excluding research unrelated to electrode fabrication or electrochemical energy storage. To gather further insights into dry electrode technologies, we welcome articles addressing, but not limited to, the following themes:—Solvent-free binder materials, including PTFE, UHMWPE, cellulose-based binders, and emerging alternatives—Binder distribution and flowability mechanisms and their influence on electrode microstructure—Uniform conductive-network formation and carbon-binder domain distribution in dry-processed electrodes—Dry mixing, powder processing, calendering, lamination, and process optimization—Fabrication of thick, high-mass-loading electrodes—Investigating microstructure uniformity through analysis technique—Comparative electrochemical performance of dry- and wet-processed electrodes—Electrochemical reaction homogeneity, cycle extension, and fast-charging performance of high-energy-density battery —Compatibility of dry processing with lithium metal anode and solid-state electrolyte for next-generation battery—Mechanical integrity including adhesion, flexibility, and conductivity within thick electrode—Ionic and electronic transport behavior in dry-processed electrode architectures—Advanced characterization and modeling of dry electrode structure and formation—Novel dry coating processing techniques—Scale-up, manufacturing readiness, and integration into high-throughput battery production—Techno-economic assessment of solvent-free electrode manufacturing—Environmental and life-cycle assessment of dry versus solvent-based processing. Topic editors: Gyujin Song, Chanhyun Park, MyungJun Kwak Source: https://www.frontiersin.org/research-topics/84339/dry-electrode-fabrication-for-lithium-ion-and-next-generation-batteriesmaterials-processing-and-electrochemical-performance