Between Pilot‐Production and Lab‐Scale: How to Approach Silicon‐Dominant Li‐Ion Battery Anodes Performance Consistency

ABSTRACT Silicon‐dominant (SD) anodes are widely regarded as a key enabler for next‐generation high‐energy lithium‐ion batteries, yet most studies remain confined to laboratory‐scale electrodes, often yielding inconsistent performance when translated to larger manufacturing environments. Here, we demonstrate a processing strategy that ensures electrochemical and structural consistency of Si‐dominant electrodes across Laboratory‐scale (LS) and Pilot‐line (PL) production, using only commercially available materials and industrially relevant areal capacities of 3.4–4.0 mAh cm − 2 . Despite the use of different mixing technologies, both LS and PL slurries exhibited comparable rheological behavior, leading to similar electrode microstructures and mechanical integrity. Electrochemical evaluation confirmed stable operations under a controlled Si capacity limitation (1000 mAh g − 1 ), enabling a reproducible comparison of degradation trends. The scalability of the approach was further validated in a 1.5 Ah stacked pouch cell, which delivered 253 cycles at C/2 with >99.90% average efficiency. These results demonstrate that careful control of slurry rheology, formulation, and processing parameters enables robust transfer of SD Electrode performance from Laboratory investigations to Pilot‐scale production, providing a practical framework for bridging early‐stage research and industrial manufacturing.