Room Temperature Fabrication of Binder‐Free Na ₃ V ₂ (PO ₄ ) ₃ /C High‐Loading Electrode Films via the Powder Aerosol Deposition Method

The powder aerosol deposition (PAD or aerosol deposition method [ADM]) and tape casting were used to manufacture Na 3 V 2 (PO 4 ) 3 /C (NVP/C) electrodes from the same synthesized powder batch. We demonstrate that Na‐based, binder‐free and solvent‐free thick PAD electrodes can be directly deposited onto aluminum current collectors. Tape‐cast electrodes were fabricated on aluminum foil to serve as a reference for electrochemical benchmarking. Galvanostatic cycling was performed at a C‐rate of C/10 between 1.5–4.5 and 2–4 V versus Na + /Na using a liquid electrolyte in coin cells. PAD electrodes with varying cathode active material (CAM) loadings were produced to evaluate the effect of loading and posttreatment on the electrochemical performance. While tape‐cast electrodes show consistent capacities (∼90 mAh g −1 at C/10), PAD electrodes delivered significantly lower specific capacities depending on CAM loading and posttreatment. By correlating delivered charge with active mass and thickness, we show that the charge extracted from PAD‐NVP/C cathode exhibit a plateau at ∼0.15–0.18 mAh, independent of CAM loading. This indicates that only a thin fraction of surface region participates in de/‐intercalation. These findings reveal the utilization limits in thick PAD cathodes and provide insight toward enabling their future industrialization.