A Processing‐Oriented Perspective on Advanced Anode Materials: From Graphite to Si‐Based Systems

This review provides a processing‐oriented perspective on the evolution of anodes for next‐generation lithium‐ion batteries (LIBs), with particular focus on Si‐based systems, and emphasizes how fabrication routes dictate structure, electrochemical behavior, and industrial scalability. Covering natural and synthetic graphite (NG, SG), nanostructured silicon (Si), Si–C composites (Si–C), silicon oxide (SiO x ), and Si–metal (Si–M) alloys, the discussion highlights key trade‐offs among capacity, cycling stability, initial Coulombic efficiency (ICE), and technology readiness levels (TRLs). Among current options, SiO x emerges as one of the most mature near‐term candidates because of its established industrial adoption and compatibility with existing graphite‐based electrode manufacturing. Si–C composites, meanwhile, represent a near‐to‐mid‐term high‐capacity upgrade pathway that can increase energy density while maintaining partial compatibility with conventional graphite processing lines, although challenges in cost, process complexity, and scalability remain. In contrast, high‐Si systems and Si–M alloys remain limited by severe volume expansion, reproducibility issues, and high processing costs. A central implication of this review is that successful commercialization will depend not on outstanding laboratory metrics alone, but on scalable and cost‐efficient processing strategies, system‐level optimization, and alignment with industrial manufacturing practices. Unlike prior reviews centered primarily on material chemistry, this work establishes a processing‐focused framework that directly connects laboratory‐scale innovation with industrial deployment.