Revolutionizing Battery Manufacturing: The Role of Dry Electrode Technology in Sustainable Energy Storage Solutions

The growing demand for high-performance energy storage, particularly in electric vehicles and grid applications, has highlighted the limitations of conventional lithium-ion battery manufacturing. Traditional wet-processing electrode fabrication, though widely used, faces challenges such as solvent waste, limited scalability, and inconsistent microstructures. Dry electrode technology (DET) offers a promising alternative by eliminating solvents and drying steps, enhancing sustainability, cost-efficiency, and performance. This review provides a comprehensive overview of DET, emphasizing key microstructural advantages including uniform material distribution, low ion-transport tortuosity, and superior mechanical strength. Various dry fabrication methods, such as binder fibrillation and dry powder spraying, are examined for their potential to enable scalable production of high-areal-capacity, high-energy-density batteries. Additionally, we explore DET applications across lithium-ion, all-solid-state, and lithium-sulfur chemistries, highlighting its effectiveness in addressing challenges related to electrode stability and interface optimization. Despite these advantages, widespread adoption faces hurdles in binder selection and process control. Future developments will require novel materials, improved interfacial engineering, and scalable manufacturing approaches to fully realize DET’s potential in next-generation batteries.