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  • Review Article
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Advanced electrode processing for lithium-ion battery manufacturing

Nature Reviews Clean Technology volume 1, pages 116–131 (2025)Cite this article

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Abstract

Lithium-ion batteries (LIBs) need to be manufactured at speed and scale for their use in electric vehicles and devices. However, LIB electrode manufacturing via conventional wet slurry processing is energy-intensive and costly, challenging the goal to achieve sustainable, affordable and facile manufacturing of high-performance LIBs. In this Review, we discuss advanced electrode processing routes (dry processing, radiation curing processing, advanced wet processing and 3D-printing processing) that could reduce energy usage and material waste. Maxwell-type dry processing is a scalable alternative to conventional processing and has relatively low manufacturing cost and energy consumption. Radiation curing processing could enable high-throughput manufacturing, but binder selection is limited to certain radiation curable chemistries. 3D-printing processing can produce electrodes with diverse architectures and improved rate performance, but scalability is yet to be demonstrated. 3D-printing processing is good for special applications where throughput and cost can be compromised for performance.

Key points

  • Conventional lithium-ion battery electrode processing heavily relies on wet processing, which is time-consuming and energy-consuming.

  • Compared with conventional routes, advanced electrode processing strategies can be more affordable and less energy-intensive and generate less waste.

  • Electrode architectures can be tailored through advanced wet processing to improve charge and discharge rate performance, at the expense of increased manufacturing cost.

  • Dry processing can simplify the electrode manufacturing process with lower manufacturing costs (~11.5%) and energy consumption (>46% lower).

  • Radiation curing technologies can have the highest electrode manufacturing throughput, whereas 3D printing can fabricate electrodes with different geometries and structures.

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Fig. 1: Electrode processing techniques.
Fig. 2: Modified electrodes manufactured by conventional slurry-based processing.
Fig. 3: Properties and performance of dry-processed electrodes.
Fig. 4: Dry processing methods.
Fig. 5: Radiation curing electrode processing.
Fig. 6: 3D-printing electrode processing.

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Acknowledgements

The submitted manuscript was created by UChicago Argonne, LLC, Operator of Argonne National Laboratory (‘Argonne’). Argonne, a US Department of Energy (DOE) Office of Science laboratory, is operated under Contract DE-AC02-06CH11357. Part of the work was performed at Oak Ridge National Laboratory, managed by UT Battelle, LLC, for the US DOE under contract DE-AC05-00OR22725. R.T. and J.L. thank the US DOE Advanced Materials & Manufacturing Technology Office and Vehicle Technologies Office (VTO) for support. Z.D. thanks the sponsorship of VTO. Y.G. was funded by the National Science Foundation (NSF 21-013), which was granted to C. Yuan, Case Western Reserve University, and is supplementary funding for Award no. 2101129 from the Division of Chemical, Bioengineering, Environmental, and Transport Systems. The US Government retains and the publisher, by accepting the article for publication, acknowledges that the US Government retains a non-exclusive, paid-up, irrevocable, worldwide licence to publish or reproduce the published form of this manuscript, or allow others to do so, for US Government purposes. The DOE will provide public access to these results of federally sponsored research under the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

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Authors and Affiliations

  1. Applied Materials Division, Argonne National Laboratory, Lemont, IL, USA

    Runming Tao & Jianlin Li

  2. Department of Mechanical and Aerospace Engineering, Case Western Reserve University, Cleveland, OH, USA

    Yu Gu

  3. Electrification and Energy Infrastructures Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA

    Zhijia Du & Xiang Lyu

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All authors researched data and wrote the article. R.T. and J.L. contributed substantially to the coordination and supervision. All authors reviewed and/or edited the manuscript before submission.

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Correspondence to Runming Tao or Jianlin Li.

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Competing interests

J.L. and Z.D. are inventors on issued US Patents 11,289,689 and 11,984,577 for method of solvent-free manufacturing of composite electrodes incorporating radiation curable binders that are licensed to Ateois; they receive royalties for this invention. J.L. is an inventor on issued US Patents 8,845,768 and 9,527,044 for proton conducting membranes for hydrogen production and separation that are licensed to Redox Power Systems, and receives royalties for these inventions; is an inventor on issued US Patents 9,847,531 and 10,374,234 for current collectors for improved safety that are licensed to Soteria Battery Innovation Group, and receives loyalties for these inventions; is an inventor on US Patent 10,910,628 for fast formation cycling for rechargeable batteries and US Patent 11,362,333 for cobalt-free layered oxide cathodes that are licensed to SPARZ, and receives loyalties for these inventions; and is an inventor on US Patents 8,956,688 and 9,685,652 for aqueous processing of composite lithium-ion electrode material, US Patent 10,684,128 for batch and continuous methods for evaluating the physical and thermal properties of films, US Patent 11,065,719 for laser-interference surface preparation for enhanced coating adhesion, US Patent 11,791,477 for roll-to-roll SOFC manufacturing method and system, and US Patents 11,916,206, 11,996,557 and 12,068,472 for battery recycling. J.L. and Z.D. declare that they are inventors on US Patent 10,601,027 for manufacturing of thick composite electrode using solvent mixtures. R.T., Y.G. and X.L. declare no competing interests.

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Tao, R., Gu, Y., Du, Z. et al. Advanced electrode processing for lithium-ion battery manufacturing. Nat. Rev. Clean Technol. 1, 116–131 (2025). https://doi.org/10.1038/s44359-024-00018-w

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