Advances and challenges in dry electrode process for solid-state batteries

Against the backdrop of global “carbon neutrality,” solid-state batteries (SSBs) have emerged as the ultimate solution for next-generation electrochemical energy storage technologies, garnering significant attention for their high energy density, enhanced safety, and extended cycle life. However, traditional wet electrode processing faces critical challenges in SSBs manufacturing, including solvent compatibility issues, process complexity, and electrode structural defects. Dry electrode process (DEP), which eliminates solvents entirely and employs direct powder mixing with in-situ fibrillated binders, significantly simplifies the production process, reduces energy consumption and costs, and enhances the microstructural uniformity and electrochemical performance of electrodes. This article systematically reviews the development of dry electrode process and its applications in SSBs manufacturing, with a focus on core processing pathways such as thermal pressing, melt extrusion, binder fibrillation, and dry spraying. Research demonstrates that dry electrode process exhibits notable advantages in the fabrication of cathodes, anodes, and solid electrolytes, particularly in the production of high-loading electrodes and ultra-thin solid electrolyte membranes. Despite significant advancements, the transition from laboratory to industrial-scale production remains fraught with challenges. Future research must further optimize process parameters, improve material compatibility, and promote scalable manufacturing to realize the widespread application of high-performance, cost-effective solid-state batteries.