Abstract

Lithium-ion batteries (LIBs) are essential for modern energy storage However, they face significant manufacturing issues related to toxic solvents, high-energy consumption, and thick electrode fabrication. Dry-electrode manufacturing provides a solvent-free alternative that reduces the environmental impact while improving productivity and facilitating the uniform production of thick-electrode through polytetrafluoroethylene (PTFE) fibrillation. This review evaluates key dry-fabrication methods, including electrostatic-spray deposition, pressing-based fabrication, extrusion-based processing, and roll-mill processing, and demonstrates how PTFE fibrillation enhances both mechanical integrity and electrochemical performance. Despite ongoing challenges, such as regulatory concerns related to PTFE decomposition under lithiation, and the need for specialized equipment, the field is progressing through the development of novel binders and process optimization. In addition, the compatibility of dry-manufactured electrodes with emerging technologies, particularly all-solid-state batteries, underscores the transformative potential of this approach. As research continues, dry-electrode manufacturing is positioned to produce more sustainable and high-performance LIBs at scale.

Keywords: dry electrode manufacturing;thick electrode;solvent-free process;lithium-ion battery