Recent Research Trends in Solvent-free Fabrication Methods for Lithium-ion and Next-generation Batteries

Dry electrode technology is gaining increasing attention as a solvent-free alternative to conventional slurry-based processes in lithium-ion and next-generation batteries. This review summarizes recent research trends in dry fabrication methods, particularly focusing on Polytetrafluoroethylene-based fibrillation processes and the role of binder and conductive additive design in achieving mechanically robust and electrochemically stable electrodes. Various approaches to improve electrode adhesion, structural integrity, and scalability are discussed, along with strategies for high-loading and thick-film electrode configurations. The review also introduces recent efforts to apply dry processing to all-solid-state batteries and lithium–sulfur systems, providing an overview of the current directions and challenges in the field.