Green and Economically Viable Dry-Electrode Manufacturing for High-Energy-Density Lithium Batteries

The global transition to electrification is driving the demand for lithium-ion batteries (LIBs) with higher energy density, lower cost, and reduced environmental footprint. Conventional slurry-based electrode manufacturing, which relies on toxic solvents and energy-intensive drying processes, poses significant economic and environmental challenges. Solvent-free dry electrode technology has emerged as a transformative alternative to overcome these limitations. This review provides a comprehensive and critical analysis of the dry process from three pivotal perspectives: economic advantages, environmental benefits, and performance superiority, conducting a multidimensional comparative analysis with slurry-process electrode manufacturing. The scientific principles behind these advantages are elucidated through microstructural and electrochemical characterization. Meanwhile, comparative life cycle assessment (LCA) data are employed to demonstrate the significant advantages of dry electrodes in terms of energy consumption and carbon emissions. Regarding application potential, leveraging Tesla's successful industrial application case, we explore the broad prospects of dry electrodes in LIBs, solid-state batteries, and other domains. Finally, in the context of the rapidly advancing dry electrode technology, we highlight the severe challenges that remain before truly achieving industrial-scale application. This work offers a holistic theoretical foundation and practical guidance for adopting dry electrode technology as a core strategy for sustainable battery manufacturing.