The battery technology landscape is evolving rapidly, driven by the growing demand for cleaner, more efficient energy storage solutions. This shift is prompting the development of innovative manufacturing techniques aimed at improving the performance of EVs and other applications, and reducing costs. Among these advancements, dry coating is widely seen as the next breakthrough technology set to revolutionize battery production, particularly in driving down costs. By enabling lower production energy consumption, faster manufacturing, reducing material waste, and eliminating the use of toxic solvents, it simplifies production and strengthens manufacturers in competing with China’s dominance. Unlike other battery technologies, most industry players agree that dry coating isn’t just possible, it’s inevitable, and widespread adoption is expected in the near future. With battery manufacturers seeking ways to scale up production while meeting sustainability goals, dry coating offers a practical solution that could accelerate the widespread adoption of EVs.
Dry Coating’s Role in Advancing Battery Technologies
In the traditional wet process, the electrode materials are mixed with a solvent to form a semi-liquid suspension (slurry), which is then applied on a thin metal foil, typically copper or aluminum. The electrode is then dried in an oven and the solvent is evaporated and recovered, ensuring that no moisture remains in the electrodes. This drying step is the most intensive carbon emission and energy-intensive phase of production. As a result, there is a growing need for alternative methods that can reduce costs and increase efficiency.
One alternative is dry coating, a method that eliminates the need for the conventional drying phase. In this process, a thin layer of active material is produced using dry active material powder and PTFE (that acts as a dry binder) which is then directly applied on the current collector. Pressure and temperature adjustments are used to bond the active material with the foil, eliminating the need for further drying. This saves costs by cutting down drying time, using less energy, reducing capital and labor expenses and emissions, in addition to space, as the drying ovens are no longer required.
Dry coating is already being integrated into existing lithium-ion production lines, with OEMs like Tesla leading the charge, allowing manufacturers to scale up rapidly and cost-effectively without waiting for major technological breakthroughs. While it’s still early days, dry coating’s ability to streamline manufacturing and lower environmental impact has led to its quick transition from an emerging innovation to a technology that’s here to stay.
Driving Major Cost Reductions with Dry Coating
Reducing costs with dry coating is rapidly becoming a reality in battery manufacturing. By eliminating the need for costly solvents, lengthy drying phases, and high-temperature treatments, dry coating drastically simplifies electrode production while significantly cutting energy consumption. This reduces operational costs while minimizing factory footprint and lowering capital expenditures, making large-scale production more efficient. As a result, without the expensive and energy-intensive steps of traditional processes, dry coating paves the way for more affordable and scalable battery manufacturing, positioning it as one of the most commercially viable advancements in the industry today.
Eliminating the Expensive and Time-Consuming Priming Process
One of the challenges in dry coated battery manufacturing is the current-collector priming process, used to enable binding of the current collector with the active material. The primer is applied on the foil, serving as a binder that melts under pressure to create an adhesive bond. However, the priming step is expensive and time-consuming, making the process more complex and prone to inefficiencies. As a result, battery manufacturers are looking for a transformative solution that eliminates the need for priming during the dry coating process. With Addionics, the 3D porous nature of the current collectors allow it to bond directly with the active material when pressure is applied, creating a stronger connection without the need for a primer. This reduces costs and simplifies the manufacturing process while also accelerating production times and minimizing energy consumption. Skipping the priming step removes the need for larger machinery, additional steps, and complex pre-processing, allowing a more efficient and cost-effective solution.
How Dry Coating Is Set to Transform EV Manufacturing
By enhancing battery production efficiency and performance, dry coating can reshape EV manufacturing. As this technology eliminates the need for traditional solvents and drying ovens, it streamlines manufacturing and reduces both time and costs. Furthermore, dry coating enables highly uniform electrode structures with superior mechanical stability. With the growing demand for more sustainable and cost-efficient production methods, OEMs are focusing on manufacturing cleaner batteries with streamlined technology that is easier to manage throughout their lifecycle. Indeed, as manufacturers strive to compete with China dominance in the battery production race, dry coating is a key advancement in the future of EV manufacturing.
The Future of Dry Coating with Addionics
While dry coating represents a significant step forward in battery manufacturing, offering a more efficient, cost-effective, and scalable solution compared to conventional methods, its full potential is yet to be realized. The structure of Addionics 3D Current Collectors enables an even more effective dry coating process. The active material is embedded within the metal framework from both sides of the current collector, leading to improved adhesion, enhanced mechanical stability, and a more uniform electrode structure. Addionics technology is a drop-in solution and can be used in any manufacturing line and with all battery chemistries, both existing and emerging. Therefore, for battery manufacturers building new factories, the shift to dry coating is an opportunity to streamline operations and accelerate the adoption of cutting-edge technology.
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