How particle shape affects battery performance

Particle morphology (i.e. size and shape) plays a critical role in determining the microstructure and performance of battery electrodes, however, the influence of particle shape remains underexplored compared to particle size or composition. This review synthesises findings from experiments and numerical simulations, on how particle morphology governs electrode behaviour, in terms of microstructure and charge transfer. Particle shape strongly affects electrode porosity, particularly for coarse active materials1, hence, incorporating realistic shapes in simulations improves the prediction of fracture behaviour and breakage risk2. At the performance level, morphological heterogeneity increases tortuosity relative to sphere-based packings, lengthening ionic transport paths3. Impedance studies show that spherical microstructures exhibit isotropic behaviour, whereas irregular shapes induce strong in-plane versus through-plane anisotropy in ionic and electronic conduction1. These results highlight morphology-driven trade-offs between packing density, transport efficiency, and mechanical durability, and emphasise the potential benefits of particle shape metrology tools for optimising electrode design.