Enabling Low‐Stack‐Pressure Silicon‐Based All‐Solid‐State Batteries: Mechanisms, Materials and Manufacturing

ABSTRACT

Silicon‐based all‐solid‐state batteries (Si‐ASSBs) are regarded as the most promising next‐generation energy‐storage technology, offering both high energy density with intrinsic safety. However, state‐of‐the‐art Si‐ASSBs typically rely on excessively huge stack pressures beyond 50 MPa to sustain solid‐solid interfacial contact and electrode integrity, far exceeding the practical pressure limits (≤ 2.0 MPa) required for scalable cell manufacturing and operation. This review systematically summarizes recent progress toward enabling Si‐ASSBs to operate under reduced stack pressures, with a discussion by four core dimensions: electrode design, interface engineering, structural optimization, and cell‐assembly approaches. Low‐pressure mechanisms enabling Si‐ASSBs operation are analyzed across multiple scale insights, ranging from active material preparation and electrode microstructure regulation to cell‐/module‐level configurations. We further synthesize recently potential studies aimed at decoupling electrochemical performance with external stacking pressure, which can be realized by in‐situ physicochemical characterization, artificial intelligence or machine learning‐assisted optimization, conductive‐elastic filler design, and the Si‐anode matched roll‐to‐roll or cold‐pressing manufacturing processes. By integrating mechanistic understanding with scalable engineering approaches, this review provides a comprehensive guidance for the rational design and practical implementation of high‐performance Si‐ASSBs under low‐stack pressure (≤ 2.0 MPa).