Dry Electrode Processing for Lithium‐Ion Battery Cathodes and Anodes: Materials, Fabrication Strategies, and Future Outlook

Abstract Dry electrode processing has emerged as a promising alternative to traditional slurry‐based fabrication for lithium‐ion battery cathodes. However, applying dry processes to anodes remains particularly challenging, as the fibrillated PTFE binder tends to decompose under low potentials, leading to severe capacity loss. By eliminating toxic solvents and drying steps, this method offers environmental and economic advantages while enabling the development of thick, high‐loading electrodes. This review provides a comprehensive overview of recent advances in solvent‐free cathode fabrication, including material selection, mechanical densification strategies, and scalable manufacturing techniques. The structural, electrochemical, and process‐related aspects of dry electrodes through categorized discussions and representative studies is analyzed. Key challenges related to material compatibility, high‐throughput production, and full‐cell integration are discussed alongside future directions. This review aims to guide ongoing research and industrial development of sustainable and high‐performance battery electrodes through dry processing technology.