<2026> Dry Electrode Process Technology for Secondary Batteries - Development Trends and Market Outlook (~2035)
Recently,
the dry electrode process has emerged as a key next-generation battery
manufacturing technology in the global battery industry. Interest in dry
electrode technology is rapidly growing across various battery applications,
including EVs, ESSs, all-solid-state batteries, and sodium-ion batteries
(SIBs). Global battery manufacturers increasingly recognize securing dry
electrode technology as a critical factor in strengthening their future
competitiveness.
The dry
electrode process manufactures electrodes by directly mixing active materials,
conductive additives, and binders without the use of solvents, followed by
processes such as rolling, pressing, and lamination. By eliminating the drying
process and NMP recovery equipment, the technology is estimated to reduce
process energy consumption by approximately 20–40% and capital expenditures
(CAPEX) for manufacturing facilities by approximately 15–30%. In addition,
shorter production lines and reduced factory space requirements make the
process highly advantageous for large-scale battery manufacturing.
Tesla is
one of the leading companies in dry electrode technology. Tesla began securing
dry electrode technology through its acquisition of Maxwell Technologies in
2019 and has since applied the dry electrode process as a core technology in
the development of its next-generation 4680 cylindrical battery cells.
Initially, a hybrid approach combining a dry anode with a wet cathode was
primarily adopted. However, Tesla appears to have addressed the application of
the dry process to cathodes by introducing a composite binder system, as
disclosed in its recent patent US2025/0364562. In this approach, polymer
binders such as PVDF, PEO, and PE are blended with PTFE. These additional
polymer binders are believed to coat the surface of the active material,
forming a protective layer that prevents direct interaction between PTFE and
the electrode active material.
In
particular, 4680 battery cells require significantly thicker electrodes and
higher areal loading than conventional cylindrical cells. They also employ a
tabless structure to achieve high power output and high energy density, making
the advantages of dry electrode technology directly relevant to their
performance and manufacturing requirements.
Dry
electrode technology is even more significant in the field of all-solid-state
batteries. Many industry experts believe that, as all-solid-state batteries
move toward commercialization, the dry electrode process is likely to become an
essential manufacturing platform rather than merely an optional technology.
However,
solid electrolytes used in all-solid-state batteries, including sulfide-,
oxide-, and halide-based electrolytes, are sensitive to moisture and organic
solvents, which can cause interfacial reactions or performance degradation
during wet slurry processing. Sulfide-based electrolytes, in particular,
require special handling during manufacturing due to the risk of generating
hydrogen sulfide (H₂S) upon
exposure to moisture.
For this
reason, dry-based manufacturing methods such as dry mixing, dry film formation,
and dry lamination offer significant advantages in all-solid-state battery
production. Since the dry electrode process does not use solvents, it can help
maintain the stability of solid electrolytes while improving
particle-to-particle contact and reducing interfacial resistance.
One of the
major technical challenges facing all-solid-state batteries is achieving
sufficient interfacial contact between the cathode and solid electrolyte, as
well as between the anode and solid electrolyte. Recent studies have reported
that dry co-rolling and hot pressing can improve particle contact and reduce
porosity, thereby enabling strong electrochemical performance. In fact,
dry-processed all-solid-state batteries have demonstrated high energy densities
exceeding 300 Wh/kg and cycle life of several hundred charge-discharge cycles,
highlighting their potential for commercialization.
In
addition, as all-solid-state batteries inherently involve high manufacturing
costs, the cost-saving benefits of the dry electrode process become even more
important. Eliminating drying equipment, simplifying manufacturing processes,
and reducing energy consumption can significantly lower overall production
costs. These benefits are expected to play a key role in ensuring the economic
viability of future mass production of all-solid-state batteries.
Major
battery and automotive companies, including Toyota, Nissan, LG Energy Solution,
Samsung SDI, and CATL, are also actively developing dry electrode technologies
for all-solid-state batteries and other next-generation batteries. In
particular, around 2030, when the commercialization of all-solid-state
batteries is widely anticipated, the dry electrode process is likely to become
a de facto standard manufacturing platform.
This
report aims to provide an outlook on the current status and near-term future of
dry electrode processing by examining key technical topics, including the need
for carbon-neutral process development in the rechargeable battery industry,
challenges associated with conventional wet processes, and current issues in
dry electrode processing. It also provides information on the latest dry
electrode process development trends among rechargeable battery industry
players, as well as recent developments in all-solid-state battery technologies
across a wide range of companies.
Strong Points of This Report
① Comprehensive technical coverage of
the background and development of dry electrode processes
② Detailed explanations of different
types of dry electrode processes and key issues associated with electrode
manufacturing
③ In-depth comparison of the advantages
and disadvantages of dry and wet processes, including their application to
battery cells
④ Detailed technical coverage of the
application of dry electrode processes to next-generation all-solid-state
batteries
⑤ Detailed information on development
trends among domestic and global companies involved in electrode processing,
materials, and manufacturing equipment
⑥ Coverage of government-supported dry
electrode research projects by country, including their key objectives and
activities
⑦ Market outlooks for dry electrode
processes from major research firms
1. Dry Electrode Process for Secondary Batteries
1.1 Need to Develop
Carbon-Neutral Processes in the Secondary Battery Industry
07
1.2 Need for Developing
Thick Electrodes for Secondary Batteries 13
1.3 Issues in Wet-Based
Electrode Manufacturing Processes 15
1.4 Background for
Introducing Dry Processes 19
1.5 Development of Dry
Electrode Processes 29
1.6 Types of Dry
Processes 68
1.7 Issues in Dry
Processes 104
1.8 Comparison of Dry and
Wet Processes 112
1.9 PTFE Fibrillation
131
2. Application of Dry Processes to Next-Generation Secondary
Batteries
2.1 Need to Apply Dry Processes to All-Solid-State Batteries 148
2.2 Case Studies on Applying Dry Electrode Processes to
All-Solid-State Batteries 153
3. Development Trends by Company/Institution
3.1 Dry Process Development Trends in Domestic and Overseas
Industries 190
3.2 Development Trends of Korean Companies 192
3.3 Development Trends of Overseas Companies 199
3.4 Development Trends of Equipment Companies 254
3.5 Development Trends of Universities and Research Institutes 330
4. Research Projects by Country
4.1 United States and European Union 352
4.2 EU Projects 353
4.3 Korea 355
4.4 Japan and China 360
4.5 United Kingdom and Australia 361
5. Market Outlook for Batteries Applying Dry Electrodes(~2035)
5.1 Market Overview for Dry Electrode Applications 361
5.2 Promising Batteries for Dry Electrode Technology Application 363
5.3 Promising Application Areas for Batteries Using Dry Electrode
Technology 364
5.4 4680 Cells and Dry Electrodes: Outlook and Market Insights 365
5.5 All-Solid-State Batteries and Dry Electrodes: A Core Platform
for Future Mass Production 366
5.6 Sodium-Ion Batteries (SIBs) and Dry Electrodes 367
5.7 LFP Batteries and Dry Electrodes 368
5.8 Capacity Outlook for LIBs + SIBs for ESS Applications 369
5.9 Outlook for Design Capacity vs. Actual Capacity of 46xx
Batteries for EV + ESS Applications 370
5.10 Capacity Outlook for 46xx Batteries Applying Dry Processes for
EV + ESS Applications 371
5.11 Capacity Outlook for LFP for ESS Applications Applying Dry
Electrode Processes (GWh) 372
5.12 Capacity Outlook for All-Solid-State Batteries Applying Dry
Processes 373
5.13 Capacity Outlook for Batteries Applying Dry Processes 374