Yangtao Liu1 Jin Liu1 Brandon Ludwig2 Yan Wang1 Heng Pan2

1, Worcester Polytechnic Institute, Worcester, Massachusetts, United States
2, Mechanical Engineering, Missouri University of Science and Technology, Rolla, Missouri, United States

An advanced power-based spraying technology was developed by us to fabricate electrodes for the lithium-ion batteries to replace the conventional slurry cast method. The additive manufacturing technology is a low cost, highly efficient way to avoid toxic NMP solvent from electrode fabrication. The removal of solvents shortened the production time from days to seconds, analyzed to reduce 20% of production cost, and enabled a more precise control of electrode microstructure during manufacturing. With the continuous processing system, the technology has a good potential to be scaled up and commercialized. Beyond the current commercial materials, we can also demonstrate this technology with a wide range of compatibility on producing electrodes, including different types of cathodes (LCO, LMO, NCM), anodes (MCMB), advanced architecture designs (Ultra-low binder recipe (<1%), high-energy thick electrodes (>280um), hierarchical micro-structured). In addition, the flexible arrangement strategy of spraying guns promoted the development of hierarchical designs to be practically available to the lithium-ion market.