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Revolutionizing Battery Manufacturing: The Role of Dry Electrode Technology in Sustainable Energy Storage Solutions
Review Article  ·  Published: 21 March 2026
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Journal of Advanced Materials Research
Volume 2, Issue 2, 2026: 97-118
Review Article Open Access

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

by
Beinuo Zhang Beinuo Zhang 1
Junnan Qu Junnan Qu 1
Jinhao Chen Jinhao Chen 1
Jiahao Lei Jiahao Lei 1
Zhicheng Zheng Zhicheng Zheng 1
Kaiqi Chen Kaiqi Chen 1 ORCID
Yikun Fang Yikun Fang 1
Pan Feng Pan Feng 1 *
Dan Luo Dan Luo 2 * ORCID
Zhongwei Chen Zhongwei Chen 2
Xinli Guo Xinli Guo 1 * ORCID
1 State Key Laboratory of Engineering Materials for Major Infrastructure, School of Materials Science and Engineering, Southeast University, Nanjing 211189, China
2 Power Battery & System Research Center, Dalian Institute of Chemical Physics Chinese Academy of Sciences, Dalian 110623, China
Corresponding Authors: Pan Feng, [email protected]; Dan Luo, [email protected]; Xinli Guo, [email protected]
Volume 2, Issue 2
Volume 2, Issue 2 2026
Received: 13 January 2026 Accepted: 04 March 2026 Published: 21 March 2026 CrossMark
Download PDF 4.85 MB Cite Metrics
DOI: 10.62762/JAMR.2026.951996
ARK: ark:/57805/jamr.2026.951996

Article Information

Published in Journal of Advanced Materials Research
Volume/Issue Volume 2, Issue 2, 2026
Pages 97-118

Abstract

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.

Graphical Abstract

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

Keywords

Lithium-ion batteries dry electrode technology all-solid-state batteries dry-processed electrodes sustainable energy storage

Data Availability Statement

Data will be made available on request.

Funding

This work was supported in part by the National Key R&D Program of China under Grant 2024YFB3715000; in part by the National Natural Science Foundation of China under Grant 22405127; in part by the Commanding Heights of Science and Technology of Chinese Academy of Sciences under Grant LDES150000; in part by the Science and Technology Major Project of Liaoning Province under Grant 2024JH1/11700013.

Conflicts of Interest

The authors declare no conflicts of interest. 

AI Use Statement

The authors declare that no generative AI was used in the preparation of this manuscript.

Ethical Approval and Consent to Participate

Not applicable.

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APA Style
Zhang, B., Qu, J., Chen, J., Lei, J., Zheng, Z., Chen, K., Fang, Y., Feng, P., Luo, D., Chen, Z., & Guo, X. (2026). Revolutionizing Battery Manufacturing: The Role of Dry Electrode Technology in Sustainable Energy Storage Solutions. Journal of Advanced Materials Research, 2(2), 97–118. https://doi.org/10.62762/JAMR.2026.951996
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TY  - JOUR
AU  - Zhang, Beinuo
AU  - Qu, Junnan
AU  - Chen, Jinhao
AU  - Lei, Jiahao
AU  - Zheng, Zhicheng
AU  - Chen, Kaiqi
AU  - Fang, Yikun
AU  - Feng, Pan
AU  - Luo, Dan
AU  - Chen, Zhongwei
AU  - Guo, Xinli
PY  - 2026
DA  - 2026/03/21
TI  - Revolutionizing Battery Manufacturing: The Role of Dry Electrode Technology in Sustainable Energy Storage Solutions
JO  - Journal of Advanced Materials Research
T2  - Journal of Advanced Materials Research
JF  - Journal of Advanced Materials Research
VL  - 2
IS  - 2
SP  - 97
EP  - 118
DO  - 10.62762/JAMR.2026.951996
UR  - https://www.icck.org/article/abs/JAMR.2026.951996
KW  - Lithium-ion batteries
KW  - dry electrode technology
KW  - all-solid-state batteries
KW  - dry-processed electrodes
KW  - sustainable energy storage
AB  - 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.
SN  - 3070-5851
PB  - Institute of Central Computation and Knowledge
LA  - English
ER  -
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@article{Zhang2026Revolution,
  author = {Beinuo Zhang and Junnan Qu and Jinhao Chen and Jiahao Lei and Zhicheng Zheng and Kaiqi Chen and Yikun Fang and Pan Feng and Dan Luo and Zhongwei Chen and Xinli Guo},
  title = {Revolutionizing Battery Manufacturing: The Role of Dry Electrode Technology in Sustainable Energy Storage Solutions},
  journal = {Journal of Advanced Materials Research},
  year = {2026},
  volume = {2},
  number = {2},
  pages = {97-118},
  doi = {10.62762/JAMR.2026.951996},
  url = {https://www.icck.org/article/abs/JAMR.2026.951996},
  abstract = {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.},
  keywords = {Lithium-ion batteries, dry electrode technology, all-solid-state batteries, dry-processed electrodes, sustainable energy storage},
  issn = {3070-5851},
  publisher = {Institute of Central Computation and Knowledge}
}

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CC BY Copyright © 2026 by the Author(s). Published by Institute of Central Computation and Knowledge. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/), which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.
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