A Comparative Review of Wet and Dry Electrode Manufacturing Processes: Opportunities, Limitations, and Challenges in the Production of Lithium-Ion Battery Electrodes

The rising demand for lithium-ion batteries (LIBs) highlights the importance of developing electrode fabrication methods that ensure high performance, cost efficiency, and environmental sustainability. Here, wet (slurry-based) and dry (solvent-free) electrode fabrication methods are compared with a focus on both anodes and cathodes. Despite its integration within an established industrial system, the wet method exhibits significant limitations stemming from the use of volatile solvents such as N-methyl-2-pyrrolidone (NMP), the high energy demand of the drying stage, and the complexity of scaling up thick electrode manufacturing. On the other hand, dry electrode fabrication eliminates the need for solvents, reduces energy use, simplifies production workflows, and improves mechanical integrity. The latter helps in the development of high-loading electrodes for next-generation high-energy density storage systems. However, dry processing introduces new technical challenges that must first be addressed, including binder activation, uniform material dispersion, the need for specialized hardware, and the development of customized equipment. By focusing on the underlying mechanisms, advantages, and practical limitations, this review aims to support the development of optimized electrode fabrication strategies that facilitate the widespread adoption of sustainable battery technologies.