Dry Coating Technology Providers

Dry Coating Technology for Battery Electrodes

Dry coating is a manufacturing method for battery electrodes that functions without the use of liquid solvents. It marks a significant shift from the conventional wet slurry process, which depends on mixing active materials into a liquid paste, applying it to a metallic foil, and then evaporating the solvent in large, energy-intensive ovens. By eliminating solvents and the drying step, dry coating technology directly addresses major cost, efficiency, and environmental concerns in battery production. This method is becoming instrumental for producing current and next-generation cells, including solid-state batteries, more sustainably and economically.

Key Characteristics of the Technology

The move away from a solvent-based system introduces several fundamental improvements to the electrode manufacturing process.

• Reduced Energy and Cost: The most direct benefit is the elimination of the large-scale industrial drying ovens and solvent recovery systems required in wet processing. This change can lower the energy consumption of a factory by approximately 30-40% and substantially reduces both capital expenditure for equipment and ongoing operational costs.
• Environmental and Safety Improvements: Conventional electrode production often uses N-Methyl-2-pyrrolidone (NMP), a toxic solvent that requires careful handling and recovery to mitigate health and environmental risks. Dry coating removes NMP and other solvents entirely, resulting in a safer work environment and a manufacturing process with a smaller ecological footprint.
• Enhanced Electrode Properties: Operating without liquids allows for the creation of thicker, more compact electrode layers with a higher concentration of active material. This increased density can lead to batteries with higher overall energy storage capacity. The process is also well-suited for sensitive materials used in solid-state batteries, which can be damaged by solvents.
• Streamlined Manufacturing: By removing the time-consuming drying stage, the dry coating process can achieve faster production speeds and requires a smaller factory footprint. This simplification of the production line contributes to greater manufacturing efficiency and throughput.

Technology Classifications / Types

Dry coating is not a single process but a category of techniques that apply dry powders to a current collector foil. The main variations are distinguished by how the materials are mixed and made to adhere to the foil.

• Dry-Mixing and Fibrillization: This approach uses a binder like Polytetrafluoroethylene (PTFE). During a high-intensity mixing step, shear force causes the PTFE to form a network of tiny fibers. This fibrous matrix physically entraps the active material and conductive additive particles, creating a self-supporting film that can then be laminated onto the current collector foil.
• Thermoplastic Binders and Lamination: In this method, a thermoplastic binder in powder form is mixed with the active materials. The dry mixture is then spread onto the current collector and heated. The heat activates the binder, causing it to melt slightly and bond the particles together and to the foil as it is pressed through rollers in a process called calendering. The roller-press system being developed by PowerCo and Koenig & Bauer is an example of this approach.
• Electrostatic Spraying: An alternative method involves electrostatically charging the dry powder mixture and spraying it onto an oppositely charged current collector foil. The electrostatic attraction holds the powder in place before it is further processed to create a permanent bond. AM Batteries’ “Powder-to-Electrode” technology uses this principle.
• Integrated Material-Collector Systems: Some approaches modify the current collector itself to improve adhesion and performance. Addionics, for instance, pairs the dry coating process with its 3D current collectors. The porous, three-dimensional structure of the foil provides a physical scaffold that helps lock the dry-coated material in place, improving mechanical stability and ion flow.

Development and Commercialization Challenges

• Material Mixing and Uniformity: Achieving a perfectly consistent and homogenous blend of active materials, binders, and conductive additives without a liquid medium is difficult. Inconsistent mixing can lead to defects in the final electrode, such as variations in density or performance.
• Binder-Foil Adhesion: Ensuring the dry electrode layer sticks securely to the thin metallic foil is essential for the battery’s longevity and performance. The bond must be strong enough to withstand the mechanical stress of calendering, cell assembly, and the expansion and contraction that occurs during battery cycling.
• Process Scalability and Speed: A process that works well at slow speeds in a lab must be adapted for high-speed, continuous roll-to-roll manufacturing to be economically viable. Maintaining quality and uniformity at speeds of 60-80 meters per minute or more requires highly specialized machinery and precise process controls.
• Quality Control: Traditional methods for inspecting wet-coated slurries are not applicable to a dry process. New in-line sensor systems and analytical techniques must be developed to monitor coating thickness, mass loading, and uniformity in real-time to ensure every part of the electrode meets specifications.

Recent Developments and Examples

• Tesla: Is widely recognized for integrating dry battery electrode (DBE) technology into the manufacturing of its 4680 battery cells, validating the process for high-volume automotive applications.
• PowerCo (Volkswagen) & Koenig & Bauer: This partnership is developing a roller press system for dry coating cathodes. The collaboration successfully completed a proof of concept in June 2025 and aims to begin full-scale industrial production by 2026, anticipating a 30% reduction in energy use.
• Fraunhofer IWS & FFB: These German research institutes are advancing the DRYtraec® process, a direct rolling method. Their goal is to industrialize the technology, with a pilot plant scheduled for commissioning in 2024 designed to achieve speeds of at least 20 m/min.
• AM Batteries: The company’s “Powder-to-Electrode” electrostatic spray method was recognized by TIME Magazine for its innovation. The process is designed to reduce energy use by up to 40% by spraying dry active materials directly onto the collector foils.
• Anaphite: This company focuses on solving the initial mixing challenge with its proprietary Dry Coating Precursor (DCP®) powders, which are formulated for easier processing. Anaphite secured $13.7 million in funding to scale up its technology.
• LiCAP Technologies: In August 2025, LiCAP commissioned a 300 MWh dry coating production line for cathodes using its Activated Dry Electrode® process. The technology is designed to be compatible with multiple battery chemistries, including lithium-ion and solid-state.
• Dürr Systems AG: Acting as a key systems integrator, Dürr is working with LiCAP and Cellforce (a Porsche subsidiary) to build a gigawatt-scale proof-of-concept line in France, demonstrating a clear path toward mass production of dry-coated electrodes.