Solvent‐Free Bonding Mechanisms and Microstructure Engineering in Dry Electrode Technology for Lithium‐Ion Batteries

Abstract Dry electrode technology (DET) presents a transformative alternative to conventional slurry‐based fabrication for lithium‐ion batteries (LIBs), offering a solvent‐free route that resolves critical environmental and manufacturing challenges. By eliminating toxic organic solvents and energy‐intensive drying steps, DET substantially simplifies the fabrication process while reducing energy consumption and production costs. Critically, this technology enables the fabrication of thick, compact, and uniform electrodes, which is essential for boosting energy density and exceptionally compatible with the manufacturing of solid‐state batteries. This review critically examines the fundamental solvent‐free bonding mechanisms that serve as the foundation for microstructural control in DET. Two of the most promising and industrially relevant methodologies are focused: Dry powder spray coating technology that involves thermoplastic binders (e.g., polyvinylidene fluoride (PVDF)), and shear‐induced polymer fibrillation coating technology that uses fibrillable polymers (e.g., polytetrafluoroethylene (PTFE)). The distinct bonding mechanisms, processing principles, and resulting microstructural characteristics of these techniques are discussed in depth, illustrating strategies for engineering optimized electrode architectures. Finally, recent advances are showcased in applying DET to high‐mass‐loading electrodes, fast‐charging cells, and solid‐state battery configurations, and identify critical directions for future research and scale‐up efforts to accelerate the industrial adoption of this sustainable manufacturing paradigm.