Advanced Manufacturing Routes for Electrodes and Cells in All‐Solid‐State Batteries: From Powder to Power

ABSTRACT

All‐solid‐state batteries (ASSBs) represent promising next‐generation energy storage systems with superior safety and energy density compared to conventional lithium‐ion batteries (LIBs). This review comprehensively examines advanced electrode and cell manufacturing processes that are critical to the commercialization of ASSBs. Electrode fabrication processes are categorized into wet and dry processing approaches. The wet processing leverages existing LIB manufacturing infrastructure for cost‐effectiveness but faces challenges due to chemical reactivity between sulfide solid‐state electrolytes and processing solvents/binders. Conversely, dry processing offers shorter production steps and improved environmental sustainability, particularly for thick electrodes. For cell assembly, bipolar stacking architectures enhance volumetric energy density through internal series connectivity, while Z‐folding methodology enables scalable manufacturing. Pressure optimization emerges as crucial for maintaining interfacial contact and electrochemical performance. The manufacturing strategies presented provide essential insights for transitioning ASSB technology from laboratory to commercial production, addressing technical and economic barriers to widespread adoption.