Scalable synthesis and electrode engineering of Li1.2Ni0.3Mn0.5O2 and LiFePO4/C cathode materials for 18650 laboratory cells

• The production of LMNO α-MnOOH and LiFePO4/C electrodes was effectively upscaled. • Electrochemical performance improves via binder–carbon black interactions. • Optimal thickness and calendering pressure were set individually per material. • The LMNO cell reached 0.33 Ah after 24 cycles, versus 0.13 Ah for the LFP/C cell. • The LFP/C cell retained over 77% capacity after 100 full-depth cycles. Cathode materials remain a critical challenge for reducing costs and improving durability in lithium-ion batteries. This work presents a scalable method for synthesizing cathode materials and optimizing slurries using a response-surface experimental design to minimize testing while identifying slurry compositions that increase discharge capacity by boosting active-material loading. Two cathode systems: Li 1.2 Ni 0.3 Mn 0.5 O 2 on an α-MnOOH template and LiFePO 4 /C, were synthesized, scaled, and characterized using Raman spectroscopy, XRD, SEM, and electrochemical analysis. Optimized slurries were then evaluated through densification, adhesion (ASTM D3359 -2), and mechanical bending/lamination tests to assess their suitability for 18650 cell assembly. Statistical analysis indicated that binder and Super P content negatively affect discharge capacity, whereas electrode thickness and Super P content positively affect it. A dry-film thickness of 30 µm was identified as optimal for calendering, resulting in better malleability and higher capacity. Custom 18650 cells demonstrated that LFP/C offers superior cycling stability and durability, whereas LNMO α-MnOOH provides higher initial capacities. Overall, this integrated workflow offers a scalable pathway from cathode synthesis to electrode fabrication and 18650 lab-cell assembly.