Year: 2026
Type: article
Abstract: The growing demand for sustainable, high-performance energy storage is accelerating the transition toward cleaner and more efficient battery manufacturing technologies. Dry battery electrode (DBE) processing is emerging as a key enabler of this shift, as it eliminates toxic solvents, energy-intensive drying, and the large-scale recovery systems required in conventional wet electrode production. In this review, we provide a comprehensive overview of DBE from the perspectives of processing technology, materials chemistry, sustainability, and application potential. Established and emerging DBE routes are summarized including binder fibrillation-based coating, powder-film formation, hot pressing, roll-to-roll lamination, and additive manufacturing. Furthermore, the influence of binder choice, powder interactions and microstructural design, on electrode integrity and electrochemical performance is investigated. The review also highlights the sustainability advantages of solvent-free manufacturing and outlines how DBE can support next-generation battery concepts, including solid-state systems. Additional dry-processible components, such as separators, membranes, and current collectors, are examined to illustrate broader opportunities for solvent-free cell fabrication. Finally, current challenges in scale-up, process control, and interface engineering are discussed, and strategies that may accelerate industrial implementation are presented. Together, these insights position DBE as a promising pathway toward more efficient, flexible, and environmentally friendly battery production.
Source: Advances in Applied Energy
Authors: Anwar Ahniyaz, Amanda Holst, Yaprak Subasi, Svenja Schreiber, Julius Gerk, Anna Pidluzhna, Dhrubajyoti Bhattacharijya, Ahmed S. Etman, Emanuel Glans, Steffen Schellenberger, Illia Dobryden, Stina Starborg, Juhanes Aydin, Agnes Digranes, Jesper Edberg, Subimal Majee, Mats Zackrisson, Nicolas Bucher, Gints Kucinskis, Mónica Cobos, Iratxe De Meatza, Susan Sananes-Israel, Andriy Kvasha, Liyuan Liu, Arno Kwade
Language: English
Subfield: Electrical and Electronic Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $4,360
OpenAlex ID: W7218559142