Scalable cathode electrode and sulfidic separator manufacturing by DRYtraec® process for solid-state batteries

Solid-state batteries (SSBs) represent a promising alternative to conventional lithium-ion batteries (LIBs) by substituting liquid electrolytes with solid-state materials, significantly improving safety and energy density. However, traditional manufacturing methods for LIBs face substantial challenges in scalability and performance once they are applied for SSBs. Wet-chemical methods are used for electrode preparation involving toxic solvents and energy-intensive drying processes. Moreover, especially for sulfidic solid electrolytes, the ionic conductivity is negatively affected by the solvent in the wet coating process. In contrast, the solvent-free fabrication of electrodes for SSBs faces substantial challenges in scalability. To address these issues, specifically dry electrode processes can be used, such as DRYtraec®. The latter enables direct calendering in a single step, from powder feeding to electrode lamination. In this study, the feasibility of coating using various process parameters is evaluated, demonstrating continuous production and comparing the electrochemical performance of these components with manual dry films and bulk powders. • DRYtraec® process enables the continuous production of NMC cathodes and sulfidic separators. • By adjusting shearing ratio and gap width, the process offers precise control over electrode properties. • Sulfidic separators exhibit distinct production domains depending on shearing ratio and gap values. • Calendered cathodes and separators demonstrated equivalent electrochemical performances than the ones made by manual process.