Solvent-free Electrode Fabrication for Next-generation Batteries: Inception or an Endgame?

Solvent-free electrode fabrication (SEF) is a revolutionary advancement in the field of battery manufacturing, providing a compelling, solvent-free alternative to conventional slurry-based processing. SEF offers significant benefits, including reduced energy consumption resulting from the elimination of toxic solvents, solvent recovery steps, a lower environmental impact, overall cost reduction, and overcoming of binder migration, encountered during the fabrication of thicker electrodes. However, the practical application of SEF must overcome key challenges, such as achieving uniform particle distribution, ensuring strong electrode cohesion and adhesion, and scaling up to meet industrial production demands. This review provides a comprehensive assessment of the current landscape in dry electrode fabrication technologies, featuring advanced techniques such as dry pressing, spray dry deposition, and 3D printing. The fundamental chemistry of materials in addition to the mechanical, and electrochemical factors critical for optimizing battery performance is elaborated with a clear focus on lithium-ion batteries (LIBs) from lab to manufacturing stage. Moreover, the article highlights significant recent advancements, identifies critical technical barriers, and outlines imperative research directions necessary to unleash the full potential of dry electrode manufacturing in the realm of sustainable energy storage.